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Lotus Elise S1 Service Manual

1. STARTER BATTERY Xt IGNITION START DROP OUT gt 2 FUSEBOX IGNITION UNFUSE Di lt E IGNITION FUSED IGNITION SWITCH 8 wo x e BRIDGING LINK 5 OR COBRA IMMOBILISER lt 12 a n gras EHC i W I dE 2 i Uo 2 uz Sx z z iz 5 E 2 2 MULTI FUNCTION O0 LAY x e e rat 3 E nc n 2 1 z z 1 7 5 2 E Aj 12 5 ab L 5 2 Ie Y E ae z 1 0 i zl j d l Ja E t La 1 2 c uU 21 i i NZ l NIS N 1 gt 5 z H N 4 1 5 dt 5 E Lotus Service Notes Section FUEL PUMP amp COOLING FAN FUSEBOX BATTERY gt IGNITION START DROP OUT gt IGNITION IUNFUSEDI gt IGNITION FUSE DI gt BRIDGING LW OR COSRA IMMOBILISER INERTIA SWITCH FUEL PUMP RELAY MULTI FUNCTION RELAY UNIT M F R U cS See FUEL PUMP am A e a QJ 5 al FUEL TANK SENDER H ai SEE SHEET 10 i X Va STUD 8MM C U MEMS 19 COOLING FAN RELAY CHASSIS REAR ul gt SHEET 2 Lotus Service Notes Sec
2. epad 48 Seui x b A Jadyeo 1804 251 2 ET ne Sender 1 GENERAL DESCRIPTION The braking system of the Lotus M111 comprises of ventilated discs all round with AP Racing 2 piston fixed calipers on the front and Brembo single piston sliding calipers on the rear A tandem master cylinder without servo assistance operates the calipers via a front rear split hydraulic circuit The centrally mounted parking brake lever operates the rear caliper pistons by control cables The AP Racing front calipers have lightweight alloy bodies housing two opposed pistons and are mounted via two bolts directly to the rear of the extruded aluminium alloy front hub carriers The Brembo rear brakes use single piston sliding calipers with cast iron bodies mounted via an adaptor plate to the rear of each hub carrier The rear calipers are also used on some versions of the Lotus Esprit A common ventilated brake disc is used on all four wheels with cars built prior to June 98 approx VIN W 3714 using discs constructed from a silicon carbide reinforced aluminium metal matrix Later cars use cast iron discs with a corresponding change in brake pad material The discs are sandwiched between the road wheels and hubs and use no additional fixings The tandem master cylinder is made by ITT and incorporates a front section to supply both front brakes and a re
3. 0 15 mm Tappets Tappet outside diameter 32 959 to 32 975 mm Cylinder head Cylinder head maximum warp 0 05 mm Cylinder head height NOW bcuseae dco eet A See SAN 118 95 to 119 05 mm Reface limit 0 20 mm ENGINE 9999 DATA TORQUE amp TOOLS ENGINE Valve springs K8 engines Free length een dee ee de 46 2 mm Fitted length er eae eU 37 0 mm Load valve closed 255 12N Load valve open 535 20N K16 Non VVC engines Free length 50 0 mm Fitted lengtes ena oso em Rees 37 0 mm Load valve Closed 250 12N Load valve open 450 18N at 28 8 mm K16 VVC engines Fre length esu 47 6 Fitted 37 0 mm Load valve closed 210 13N Load valve open 440 22 N Valves K8 engines Valve stem diameter EE 6 960 to 6 975 mm Exhaust EE 6 952 to 6 967 mm Valve guides Inside diameter 7 000 to 7 025 Valve stem to guide clearance a ie deen oa area Ete 0 025 to 0 065 mm Service limit 0 07 mm Exhaust tes 0 033 to 0 073 mm Service 0 11 Valve
4. a D a FUEL PUMP FUEL PUMP RELAY SEE SHEET 2 oe t Q 0 RHC CHASSIS REAR dor aile a Lotus Service Notes Section MN gea STOP amp REVERSE LAMPS FUSEBOX BATTERY D IGNITION START DROP OUT gt L FUSEBOX IGNITION UNFUSED gt IGNITION FUSED gt E RAS gjo gt INSTRUMENT PACK P SEE SHEET 10 HORN RELAY SEE SHEET 4 c TO DIAGNOSTIC CONNECTOR 5 SEE SHEET 3 a ic 05 TOP LAMP SWITCH lk s REVERSE LAMP SWITCH 1 6 ec 2 lt 1 1 Pane D 1 i a D lt gt 7HMSL 2 Bs o Lu cane 2H LAMP 3 REVERSE Ge d e m a 1 i i i t RRC TRHC TREC SHEET 6 Lotus Service Notes Section MN DIRECTION INDICATORS amp HAZARD LAMPS FUSEBOX BATTERY gt IGNITION START DROP OUT gt FUSEBOX GNITION UNFUSED gt 9 IL IGNITION FUSE DI gt HAZARD SWI TCH 12 SIDEL AMPS SEE SHEET 9 HAZARD FLASHER SWITCH Top Ly 1 1919 ALARN 70 ALARM SEE SHEET 485 Serge SEE SHEET 445 i ii d MAIN 4ARNING LH LAMPS RH LAMPS gt SHEET 7 Lotus Service Notes Section MN HE ADL AMPS BATTERY gt
5. SPLICE BB SPLICE AA MAIN HARN F P FP HC2 SG FTU CAVD SPLICE SC2 RACE OPTION CONN CAV 4 RACE OPTION CONN CAV 3 d OPTION CONN CAV 8 LAP TIME RACE OPTION CONN cav 7 ROTARY CON 2 RACE OPTION CONN 5 ROTARY CON 1 4 RACE OPTION CONN CAV 5 DRIVER BUTTON HIGH BEAM d FLASH FROM STALK SEE SHEET 11 4 OPTION ONN 11 AIR TEMP RACE OPTION CONN CAV 10 ENGINE CHECK OPTION CONN CAV 9 DOOR OPEN REAR FOG SEE SHEET 15 AUXILARY RELAY SEE SHEET 13 HEADLAMPS SEE SHEET 11 SPEEDO TACHO CAV 1 ge riet U 2 SPEEDO TACHO PEEDO TACHO 4 7 RACE OPTION 7 CONNCAV2 RACE OPTION CONN CAV 1 OPTION 12 Lotus Service Notes SPLICE SEE SHEET 1 SPLICE E IGN COIL 2 SENSOR FUSE B4 7 5 USED BULK 5 SPLICEB SEE SHEET IMHC 11 8 IMHC 12 SEE SHEET 1 AHC 14 SEE SHEET 1 BULK 41 LG SEE SHEET 10 ALARM SPLICEN gt gt 2 FUSE 10 amp OPTION SIREN CONN P FUSE A2 Samp SPLICE FUSE C1 10amp BULK34 CHMSL HC Bin AHC 8 lt SEE SHEET 6 FHC 5 c RK SEE SHEET 6 4 SPLICE RU 17 cw 2 4 ALARM CONTROLLER META SYSTEMS M99T2
6. ENGINE HARNESS CONNECTOR EHC BLUE BLUE ENGINE HARNESS CID I CONNECTOR 2 He 2 ENGIN HARNESS EB cay 029 SN CTOR 3 EUG 3 Sr BSE E em ALARM HARNESS 4 RIT IDEE ac wMOB ILISER CONNECTORS 9 BEDS KEE sys E 09 felie FIle SHEET 15 Lotus Service Notes Section FUSEBOX 22 21 20 19 18 17 16 15 14 12 PM OU E 16M u 0 9 8 7 6 5 43 2 1 EE 22 2 ESSE RI EM ERE NO RATING APPL ICAT ION 01 REAR LAMP Hs 2A ALARM 03 54 INTERIOR FAN 71 04 5A WIPER MOTOR 5A PEVERSE LAMP 06 7 5A DIRECTION INDICATORS 07 5 TONI TION SERVICES 1 08 7 5A STOP LAMPS amp BATTERY SERVICES 29 HAZARD LAMPS 10 SA HCRN 71 E 125 ALARM amp PVTERLCR LAMP S 2 15 lt ENS FAN 13 RER CLING FAN PAE 15 204 C GAR LIGHTER 6 ZA SIE AND Lu 5 MP 34 8 20 3 ZA E ERI 223 x E opens io icem 2 ai 28 DAT N um 22 moms WirlcFUSES qM B up RAT
7. bolt s must be fitted Use new screw supplied with seal kit ENGINE Rear timing belt backplate screws 16 VVC engines Rear timing belt cover screws K16 VVC engines Rear timing gear bolts K16 VVC engines RH engine mounting bracket bolts Rotor arm screw Spark plugs Spark plug cover screws Thermostat housing bolts Alloy housing Thermostat housing bolts Plastic housing Thermostat housing to cylinder block bolt Timing belt tensioner bolt Automatic tensioner Timing belt tensioner pulley Allen screw Manualtensioner Timing belt tensioner pulley backplate screw Manual tensioner Timing belt tensioner pillar bolt Timing belt lower cover screws Timing belt rear cover screws Timing belt upper front cover screws Tighten in sequence New Patchlok bolt s must be fitted Use new screw supplied with seal kit 6 DATA TORQUE amp TOOLS ENGINE Hesse Piston Ring Clamp K16 VVC Housing Oil Seal Remover Centre Bolt Valve Lifter Basic Tool Valve Lifter Adaptor Camshaft Locking Tool Locking Tool Flywheel Not Fitted With Reluctor ing Crankshaft Rear Oil Seal Replacer Tool Vaive Guide Remover Replacer Depth Gauge All K16 Engines Nylon
8. gt e e e lt SC 5 eet 9 SECTIONED VIEW OF Oil guide plate Input shaft assembly Gear case Reverse idler shaft bolt Reverse idler gear Breather pipe and bracket Differential housing Access plug output shaft bearing circlip a IS SEL TE TE ET TTD DESCRIPTION AND OPERATION SE AM 37M1162 Output shaft assembly Shift arm assembly and interlock Selective shim Final drive assembly Speedometer drive pinion housing Selector shaft Oil drain plug Oil filler level plug DESCRIPTION The 5 speed constant mesh gearbox employs single helical gears for speed transmission and final drive The input shaft carries the primary input gear reverse pinion 2nd gear and 3rd 4th and 5th gear synchromesh hubs and idler gears it is supported by two ballraces End float is controlled by selective circlips and a Belleville washer Its short input end eliminates the need for support in the engine crankshaft The output shaft carries the final drive pinion 1st idler gear 1st and 2nd synchromesh hubs 2nd speed idler gears and 3rd 4th and 5th gears The shaft is supported in the differential housing by a parallel roller bearing and depending on application is supported in the gearcase by either a double ballrace or a single ballrace and roller bearing Pinion location is controlled by a sele
9. gt L H e Chassis outrigger T Door restraint spring plate Hinge bracket stator Door beam hinge rotor Sa 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 Door beam pivot bearings The door beam hinge uses two self lubricating plastic top hat section thin wall bearings pressed into the hinge stator bracket Inside each bearing is fitted a hat section steel rotor bush clamped to the door beam extension by an M10 cap head screw threaded into the door beam EE EE CEN SE TT C O S URN Page 12 Lotus Service Notes Section The door beam extension also Rubber rates a check flange which abuts against a bung rubber strip on the hinge bracket to limit door opening angle A spring steel plate fixed to SJ gi 4 p beam abutment flange when the door is fully Plastic bearing open in order to provide a sprung restraint for the door in this position To remove the door assembly or for access to the door pivot components the two M10 cap head rotor bush retaining screws Door beam should be removed and the door assembly hinge ro
10. Solenoid vaive Purge port to intake plenum Vent port to atmosphere Tank port to fuel tanks Activated charcoal Central tube Liquid trap Page 11 Lotus Service Notes Section LH The top side of the charcoal bed is connected via a port in the top of the canister to atmosphere A purging port controlled by a solenoid valve on the top of the canister connects the tank vent and underside of the charcoal bed with a port on the throttle body such that when the valve is open the depression in the engine intake draws air through the charcoal bed to purge the canister of vapour and prepare the charcoal for further adsorption Control System The canister purge valve is controlled by the engine management ECM which keeps the valve closed unenergised when the engine is cold or idling in order to protect the catalyst and maintain idle quality At coolant temperatures above 75 C and engine speeds above 1600 rpm the ECM opens the valve and allows purging of the charcoal to take place burning the resultant gas in the normal combustion process Roll Over Valve The roll over valve is fitted on a bracket integral with the filler neck and is positioned above the neck within the flying butress of the rear clamshell The clamshell must be removed Sub section BN 5 for access to the valve Roll over valve Valve mounting bracket Filler neck flange To charcoal canister is Filler neck breather spigot Page 12
11. Difference between rim measurements overall toe out oa a eegen nn Ye ee yt lt FRONT Individual toe out ux angle 26 1998 02 didi Lotus Service Notes Section CG 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 Gaiter Track rod end flats Steering arm Steering track rod Locknut 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
12. FUSE SEE SHEET 9 DIP SWITCH MAIN BEAM REL AC PACK MAIN BE AM INSTRUMENT WARNING 1 i o pese i S i gt a 2 5 ai 2 5 E a Prac i TFC FHC H 5 E EU 2 5 4 1 gt i gt S i TN LH LAMP LAMP S LH RH L AMPS amp LAMPS 2 a d a a eee trac rur is FHC FHC e o o ale L E gt SHEET 8 Section MN E Lotus Service Notes SIDELAMPS amp FOG LAMP BATTERY com c gt cm gt eee 9 A 2 DEF aH 9 o t i 5 r A H Or 5 Lu 5 _ LH gu a 1 283 E a SE 4 5 m iu Ss D n H i ES EL EI E pz 3 z z z I E 1 o o 1 r 5 5 5 o i ell A Li p 1 i 2 11 1
13. Hub Hub carrier 4 Remove the hub clamp bolt and washers noting that LH hub M12 bolts are LH thread M16 bolts are RH thread for both sides and press the hub out of the bearing If necessary use a puller to remove the inner race from the hub spigot 5 Remove both circlips from the hub carrier and press out the bearing 6 Before fitting the new bearing clean any corrosion from the bearing bore outside of the circlip grooves and fit one circlip into position Heat the hub carrier in an oven to 90 for at least 20 minutes before pressing the bearing assembly into the carrier to abut the fitted circlip Retain by fitting the second circlip 7 Supporting the inner bearing race press the hub fully into the bearing It is recommended to fit the M16 clamp bolt set but if the original M12 bolt is to be re fitted fit the bolt from the outside inwards with RH thread on RH side LH thread on LH side M16 bolts are not handed and should be fitted from the inside outwards with a plain washer and the bearing dust shield beneath the bolt head as shown The smaller of the two special stepped washers locates against the hub and the larger against the bearing 1998 03 Lotus Service Notes Section CG Tighten the hub clamp bolt nut M12 77 Nm M16 210 Nm 8 Re assemble the suspension in reverse order to dis assembly referring also to sub section CG 4 Pump the brake pedal to reposition the pads before driving the car
14. Lotus Service Notes section EE ENGINE SECTION EE M111 ELISE Sub Section Page General Description EE 1 1 Maintenance Operations EE 2 1 Engine Removai Replacement EE 3 5 Special Tools EE 4 6 Page 1 Ken Lotus ServiceNotes Section EE Lotus Service Notes Section EE EE 1 GENERAL DESCRIPTION The 1 8 litre 16 valve four cylinder engine used in the Lotus Elise is supplied by Rover Group and is designated K16 A full description and overhaul procedure for this unit is contained in the Rover Overhaul Manual RCL 0057ENG a copy of which follows References in this manual to K8 engine versions should be disregarded EE 2 MAINTENANCE OPERATIONS Engine 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 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 to the sump so readily and the dipstick will di
15. Lotus ServiceNotes Section Lotus Service Notes Section BN Rear channel top fixing The rear guide channel is secured by two screws through the bottom face of the door shell into captive spring steel nuts on the chan nel bottom flanges and a bracket at the top end fixed by the door beam top rear fixing bolt The channel must be positioned to allow 2 the glass to slide smoothly and with an in Id Rear ward tilt to provide adequate contact with the guide door glass weatherstrips and roof Spacer channel washers are fitted as required between the rear channel top fixing and the door beam To replace the rear guide channel or the channel inserts silent channels the door glass should first be removed see above The inserts are self locating in the channels but may require some lubrication with a sili cone spray before fitting but take care not to contaminate the stud carrier adhesive on the bottom of the door glass Guide channel lower fixing BN 10 DOOR SEALS Drop Glass Inner Waist Seal The hollow section inner seal is flocked on its glass contact surface and is pressed onto a horizontal metal flange bonded to the door inside top edge The seal should be removed before the door glass is withdrawn from the door Drop Glass Outer Waist Seal The door glass outer waist seal has a wipe section flocked on its inside surface to seal against the glass and is secured by double
16. condenser Condenser Condenser mounting support frame grommet Fan motor mounting brackets Cooling fan 7 Release the radiator mounting panel from the crash structure and lift away the complete assembly 8 To remove the condenser from the pack remove the cooling fans and release the condenser mounting frame from the radiator The condenser is supported in the frame by four spigots in rubber grommets 9 Refit the condenser in reverse order to removal with the following notes If a new condenser is to be fitted add 30 cm 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 88 kg of R134a Refill the cooling system see sub section KF 3 a EE EE 2000 n4 rage is 11 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 mounted on the RH side of the front crash structure and houses the trianry switch If the switch or receiver drier is to be replaced the refrigerant must fir
17. AA canister purge o gt 7 i SS SAEPE Breather Fuel pressure connection ea regulator valve to backplate XN connection connection to backplate IAC connection to underside IAC stepper motor of throttle bodies Air Cleaner The Exige uses two identical Pipercross conical foam air cleaner elements contained within the air intake trunking a primary filter mounted at the inlet end of the trunking and a secondary filter mounted immediately after the resonator valve at entrance to the airbox When the vehicle is operated in a relatively clean environment the primary filter should be cleaned every A service and the secondary filter every B service but where a dusty or smog laden atmosphere prevails more frequent servicing will be required dependent on the level of pollution When removing either filter take care not to contaminate the engine side of the duct or airbox with dirt Follow the filter manufacturer s cleaning instructions 1 Dislodge any large embedded dirt by tapping the filter gently Brush with a soft bristle brush to remove other dirt 2 Spray Pipercross foam air filter cleaner liberally onto the entire filter Let soak for 10 minutes 3 Never use other cleaning agents e g gasoline caustic strong detergents or solvents Never use steam cleaners or a high pressure car wash Doing so will invalidate the warranty 4 Rinse off the filter with low pressure tap water from the c
18. SERVICE A renas Fit protective covers to seats footwells steering wheel amp rear body Lubrication Renew engine amp filter A X X X OPERATION DESCRIPTION 2 Inspect engine amp transmission for oil leaks 4 Check transmission oil level severe service conditions dusty areas or cold stop start driving change twice as frequently or as required enew air cleaner element refer above x R Renew spark plugs 7 auxiliary drive belt condition Renew cam belt Renew fuel filter CH Connect Lotus Check scanner tool and run Pre Test d Cooling System 12 Inspect radiator hoses amp pipework for damage or leaks Clean radiator finning 13 Check coolant level 4 Braking System 15 Inspect parking brake adjustment 12 morths 16 Inspect operation of brake tell tales T xx i 17 inspect brake pad thickness amp disc condition n conditions where the brakes are subject to heavy use inspection may be required more frequently 18 Inspect brake hoses pipes amp hydraulic units 9 Check brake fluid level 20 Renew brake clutch fluid Steering amp Suspension Inspect dampers for leaks amp performance d lt gt gt Inspect condition of driveshaft gaiters I
19. level should up to the level of this hole EX drain plug in the underside of the casing LIN Mtl square socket plug permits the oil to be ETS drained prior to transmission removal or re pair Dry fill capacity 2 4 litres Refill 2 1 litres Drain plug FH 4 DRIVE SHAFTS A driveshaft assembly comprising a steel shaft with a constant velocity joint at each end is used to transmit the drive from each differential output gear to the rear wheel hub The two shafts are of unequal length due to the offset transmission housing with the longer shaft on the right hand side Both driveshaft assemblies use plunging tripod type inboard joints and six ball Birfield type outboard C V joints outboard joint is available as a service part as is the inboard joint complete with shaft Replacement gaiter kits are available for both joints 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 Clicking noises torque reversal clonks or shudder and vibration when accelerating are all possible symptoms of worn joints It should not be possible to discern
20. 19 y esou Xue aul Bulsuas ainssaid 1114 Ja siuea 48 siue2 BAILA jeoorey pjouajos eBand B yeu poq eio Jett asoy 14 1 1 4 JOY LNOAVT IVH3N39 WALSAS 1304 Page 2 Lotus Service Notes Section LH LH 1 GENERAL DESCRIPTION The 36 4 litre 8 0 imp gall fabricated steel fuel tank is mounted within the chassis crossmember be tween the passenger compartment and engine bay with the fuel filler neck connecting to the right hand top of the tank and the fuel pump fuel gauge sender unit mounted into the left hand top surface The modular fuel pump sender assembly uses an electric motor to power a three stage impeller type pump system submerged within the tank and incorporates a reservoir canister to avoid fue starvation from surge effects caused by vehicle acceleration and cornering forces The supply pipe from the pump is routed via a replaceable fuel filter mounted at the left hand side of the engine bay before connecting with the left hand end of the engine fuel rail The fuel rail supplies all four injectors and is fitted at the right hand end with a pressure regulating valve which maintains the pressure of fuel supplied to the injectors at 2 0 to 3 0 bar dependent on engine load Excess fuel is returned to the tank via a fuel return line The constant circulation of fuel through the in line fuel filter fuel rail pressure regulator valve and return line helps avoid exces
21. CAUTION Timing belts fitted to engines with manual timing belt tensioners are not interchangeable with belts fitted to engines with automatic tensioners 124974 NOTE Two types of timing belt tensioner are fitted to K16 engines type Aisa manual tensioner fitted to some K16 non VVC and all VVC engines Type B is an autornatic tensioner fitted to some K16 non VVC engines Commencing engine numbers for the automatic tensioner are listed in Information The tensioners and their timing belts are not interchangeable The manual timing belt tensioner spring fitted to K16 non VVC engines is fitted with a sieeve whilst on VVC engines only a spring is fitted 1 Slackenibottom bolt and remove 5 screws securing timing bett upper front cover h EC 1 i NOTE Remove bottom bolt when cover is Ge not sfotted 7 2 2 37 z AJ dr 2 Remofe timing beltupper front cover and seal L7 04 4 OVERHAUL ENGINE Hesse Flywheel not fitted with a reluctor ring 18G 1570 6 Fit flywheel locking tool 18G 1571 7 Secure with 2 bolts M124947 Flywheel fitted with a reluctor ring NOTE VVC camshaft timing gear marks SCH are shown in the inset on the illustration 3 Rotate crankshaft clockwise to align camshaft gear timing marks 90 BTDC CAUTION Do not use camshaft gears gear retaining bolts or timing belt to rotate crankshaft i 1861674 4 Fit camshaft gear loc
22. Symptom The alarm triggers for no apparent reason Possible cause When the transmitter key is used to disarm the system if the alarm had been triggered during the armed period a diagnostic code will be displayed by the alarm tell tale until the ignition is next switched on The flash codes are interpreted as follows Single flash followed by 2 second break Caused by a door engine lid or front bonnet sensor A sensing switch may require attention Ihree flashes followed by 2 second break Caused by the intrusion sensor If there are no loose or moving objects or animals in the vehicle the sensitivity of the sensor may need adjustment by your dealer Four flashes followed by a 2 second break Caused by the ignition circuit being energised Note that as previously the security function of the Lotus Check scanner tool is for use only on vehicles with the base Lucas alarm unless matching a replacement MEMS 1 9 engine management ECM or Lucas 5AS security ECM Technical Helpline In case of diffilculties with alarm system diagnosis a Cobra Technical Helpline is available on 01923 479206 Disconnecting the Vehicle Battery If the battery is to be disconnected note the following precaution Immediately before disconnection mobilise the engine using the transmitter or touch key with ignition off and disconnect the battery within one minute If disconnected after this time or when immobilisation is in effect the siren will sound fo
23. 1 GENERAL DESCRIPTION The driving element of the clutch assembly consists of the rear face of the engine flywheel and a pres sure 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 mounted on a fabricated steel bracket attached to the transmission case The master cylinder is connected to the fluid reservoir of the brake master cylinder and uses a flexible synthetic pipe steel braided on later cars routed through the LH sill to connect to the slave cylinder The slave cylinder operates a release arm which is connected by shaft to the release fork inside the clutch housing The fork presses the ball type 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
24. 2 Release the clutch master cylinder from the pedal box Remove the two Nyloc nuts and flat washers from inside the pedal box and ease the cylinder clear of the pedal box to disengage the pushrod 3 From within the footwell release the ball jointed rod from the throttle pedal 4 Twist and withdraw the brake light switch from the top rear of the pedal box 5 Disconnect the ventilation air intake hose from the diverter flap housing on the scuttle and release the screw securing the housing from within the intake aperture Move the housing aside to allow the pedal box fixings to be withdrawn 6 Remove the pinch bolts and disconnect and remove the steering column intermediate shaft 7 Remove the three M6 screws securing each end of the pedal box to the scuttle beam brackets and withdraw the complete pedal box downwards into the footwell 8 With the pedal box removed the space bush and throttle pedal may be slid off the end of the pivot shaft The shaft may be withdrawn after removal of its two retaining bolts freeing the brake and clutch pedals and their thrust washers Note that brake and clutch pedals are fitted with two top hat section plastic pivot bushes with a plastic thrust washer fitted each side of both pedals The throttle pedal uses a single bush fitted from the inboard side with a thrust washer on the inboard side and a pivot bush used as a spacer between the pedal and the scuttle bracket Pedal shaft Pedal pivot Pivo
25. Concept 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 cock pit 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 soft top roof may be erected in conjunction with a rigid rear window and roll bar fairing Rear Window amp Roll Bar Fairing To allow the soft top roof to be carried on board and erected at will the roll bar fairing should be fitted together with the glass rear window Running in this configuration may also reduce cockpit air turbulence and restrict the backflow of hot air from the engine bay outlet vents Using the soft top roof without the fairing and rear window is not recommended Fit the rear window into the moulded channel in the body with the rubber seal on the forward side of the glass Place the fairing onto the roll over bar and press the glass top edge against the flange on the fairing to compress the seal and allow the window to be retained by the two tangs Hook the single over centre latch at each end of the fairing with its notch on the body and close the latch Latch handle Roll over bar fairing me d Window retaining tang 30 31 To remove the window and fairing press down the safety catch before disengagin
26. M124973 CAUTION In order to commonise exhaust camshafts between VVC and non VVC engines modified exhaust camshafts incorporating a reluctor ring are fitted to later engines these camshafts are not interchangeable with those fitted to early engines Commencing engine numbers for the modified camshafts are listed in Information 33 Remove and discard exhaust camshaft oil seals 34 Using a stick magnet remove 16 tappets from cylinder head Retain tappets in their fitted order and invert to prevent oil loss OVERHAUL 41 ENGINE Tappets inspection 1 Check tappets for signs of wear scoring and overheating 2 Measure outside diameter of tappet measurement must be taken half way along tappet body Tappet outside dia 32 959 to 32 975 mm 3 Ensure oil hole in each tappet is clear and keep them inverted to prevent oil loss NOTE Retain tappets in their fitted order 12M1771A Non VVC engines CAUTION A modified tappet has been introduced and will be supplied as a replacement for all non VVC engines The above illustration show the early tappet A and modified tappet B When the modified tappets are already fitted to an engine they may be replaced on an individual basis but may only be fitted as replacements for early tappets in cylinder sets VVC engines are lighter than those fitted to non VVC engines and whilst similar in appearance to the early tappets A illustrated above it is
27. Securely attach a draw wire to the rear end of the pipe and withdraw the pipe from the front services compartment leaving the draw wire in its place Use the wire to draw the new clutch pipe into place slave cylinder end leading from the front services compartment Note that the new pipe is supplied already bound with anti rattle foam Routed through scuttle baffle panel Wrapped in foam sleeve Routed inside sill panel Clip with A082W6587F onto heater pipe Tie wrap A082W6324F onto clutch pipe EE 1998 02 Lotus Service Notes Section On RHD cars Use an M12 female M12 female connector to join the rear end of the straightened old pipe to the front end of the new Draw the pipes through into the left hand side of the front services compartment before continuing to feed the pipes behind the windscreen demist duct to the master cylinder Fit the pipe grommet into the scuttle baffle panel On RHD cars fit the U bend connector onto the front end of the new pipe and tighten to 20 24 Nm Connect the new pipe to the master cylinder and tighten to 20 24 Nm Connect to the slave cylinder and tighten to 20 24 Nm At the rear end of the sill where the pipe enters the engine bay secure the lagged clutch pipe to the heater return pipe using in each of two places a pair of interconnecting clips pipe clip AO82W6587F and tie strap clip A082W6324F Use of these clips ensures that the two pipes are sep
28. 2 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 53 3 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 HE 3 COLU MBLY Column lower mounting bracket Alarm module instrument support bracket Break out insert Column support bracket Turn amp flasher switch Intermediate column Trim pad support Column lock assembly Upper Chassis bearing scuttle housing Wiper beam Trim pad switch Page 4 Kong Lotus ServiceNotes Section HE Lotus Service Notes Section 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
29. Ad t Ht B HOIIMS NYOH Ge 5 YOUU 21 NI o Ed 5 E m d md Md o 8 or 8 dl HOLIMS 8000 CN ma gt el CV uL aee m Md Ms Md Md o ch 8 2 8 Y 39N 155Yd HIIING 0000 e 9k G EE 1400 i ie Lube he HOLIMS LTNNORR o Se 5 E 2 Gt RL 76127 S d Ss He roro d Die M Tg 937 Wavy M Lotus Service Notes Section MN ALARM 4 IMMOBILISER COBRA FUSEBOX FUSEBOX BATTERY IGNITION START DROP OUT FUSEBOX IGNITION UNFUSED ge IGNITION FUSEDI n o zz Ez Zt 25 OIRECTION INDICATORS SHEET 71 INSTRUMENT PACK BIO SPLICE TO SPLICE F 5 SET To s o e i d 2 lt d IN 5 COBRA a a lt Ye D SEE SHEET I a START RELAY IGN SWITCH D Al N 5 D 2 em a a 1 5 Ic IC ic OSHC 10 12 cies Ed a 215 cUT2 4 CODE 5 Sz 2 12 570 3 S 79 cuts IMMOBILISER SP 82419 5 E 8 8 3 8 or GND e a Ic a 6 IHC 9 E 3 2 9
30. Each section starts with a contents page listing the information contained within Some sections are divided into sub sections such as Description and Operation Adjustments Repairs and Data Torque and Tools To assist filing of revised information each of the sub sections is numbered from page 1 Each Adjustment and Repair procedure is fully illustrated showing a number against each text item Service tools are shown in use where usage is not obvious Each illustration appears before the text which refers to it Adjustment and Repair operations also include relevant data torque figures and useful assembly details WARNINGS CAUTIONS and Notes have the following meanings WARNING Procedures which must be followed precisely to avoid the possibility of injury CAUTION Calls attention to procedures which must be followed to avoid damage to components NOTE Gives helpful information References References to the LH or RH side given in this manual are made when viewing the vehicle from the rear With the engine and gearbox assembly removed the crankshaft pulley end of the engine is referred to as the front Operations covered in this manual do not include reference to testing the vehicle after repair It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concemed Dimensions The dimensions quoted are
31. Late type anti roll bar mounting Anti roll bar Bottom wishbone Hub carrier Wheel hub Lower steering swivel joint c34 SE gt 1998 02 Lotus Service Notes Section CG 1 GENERAL DESCRIPTION The fully independent front suspension comprises on each side of the car upper and lower fabricated tubular steel wishbones with a concentric coil spring telescopic damper unit picking up on the outboard end of the lower wishbone An extruded aluminium alloy hub carrier houses a dual taper roller bearing which sup ports a steel hub equipped with 4 wheel studs A forward mounted tubular steel anti roll bar is supported in chassis mounted pivot bushes and is operated via short ball jointed drop links from the lower wishbones 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 Both upper and lower steering swivel ball joints are pressed into housings incorporated into the outer ends of the upper and lower wishbones 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 ofthe steering lower swivel joint is secured in a forged steel plinth bolted to the bottom of the hub carrier by four M10 setscrews The spring damper unit acts between the outer end of the lower wishbone and the chas
32. Lotus Service Notes 340R L N UN N gt HAZARD SWITCH INSTR 20 INSTR 19 DI SWITCH BULK 40 HAZARD FLASHER MODULE FHC 1 CAV 1 BULK 39 RH SIDE LIGHT LH LHC CAV 4 CAV 3 DW RH LIGHT lt SPLICE W Q9 SPEISEN CONN CAV 4 62 69 NS RH HDL HC LH HOL HC CAVC CAVC LH HDL HC RH HDL CAVD cavo B sheet 6 Lotus Service Notes 340R FUSE A18 25 HEATED FRONT SCREEN RELAY INSTRUMENT CONTROLLER CAV 12 SEE SHEET 8 sheet 7 Lotus Service Notes Gu SENDER HEADLAMPS SEE SHEET 11 SEE SHEET 15 SPLICE HEADLAMPS SEE SHEET 11 SEE SHEET 40 SEE SHEET 14 CN ECM PIN 5 amp BULK 36 BULK 43 OPTION RW 7 WITCH HIGH BEAM TRIGGER FROM STALK uw SEE SHEET 11 SIOELIGHTS SWITCH REARFOG 7 SEE SHEET 12 lt LIGHT SWITCH RY 4 RY 11 BRAKE FLUID SCREEN SWITCH BLG HEATED FRONT 4 SCREEN SEE SHEET 7 SPEED SIG SEE SHEET 3 SIDELIGHTS SEE SHEET 12 lt DIAL NEG DIAL POS HEATED FRONT HANDBRAKE SPLICE 2 CASE STUD SWITCH 18 19 20 CN PRESSURE SWITCH ZN ZN LHD DI SEE SHEET 6 sheet 8 NU GR GW SPLICE 55 ZN ALTERNATOR SEE SHEET 1
33. PK 7 V 7 7 SEE SHEET 9 IMMOBILISER LED 1 CONN 1 at CONN OPTION OP CONN 2 sheet 10 Page 38 BALER N ON UN B N ON LU FROM INSTRUMENT CONTROLLER CAV 28 SEE SHEET 8 UR b FUSE A22 15 amp FROM INSTRUMENT CONTROLLER CAV 42 SEE SHEET 8 uo COLUMN STALK SPLICE A SPLICEA DIP BEAM RELAY o1 Le a mm mn HIGH BEAM RELAY IGH BEAM CAV 8 SEE SHEET 8 GUN iau FUNCTION CAV 33 SEE SHEET 8 sheet 11 NU NU FUSE A20 7 5 amp FUSE A21 7 5 amp uy FHC 1 FHC 2 CAV 2 uy uy SPLICE H CAVA CAVA DIP BEAMS LH RH CAVA CAVA HIGH vD BEAMS cova CA LH RH SPLICE CAV B 39 SPLICE SIDELIGHT RELAY CENTRE CONSOLE SWITCH STACK ov CONTROLLER CAV 10 INSTRUMENT CONTROLLER CAV 14 SEE SHEET 8 SPLICE SPLICE J RO RB BULK 33 BULK 32 FHC 2 FHC 1 SPLICEL caves RO RH SIDE LIGHT CONN CAV 3 RH HDL HC RO T CHMSL HC LH HDL HC RH LHC 4 CAVB RH LHC RH HOL HC CAV 1 LH LHC CHMSL HC LH HDL HC CAVD 1 CAVD FUSE 14 Wamp AUXILIARY SOCKET RELAY NOTE SOCKETS WILL ONLY OPERATE ABOVE 2000RPM A INSTRUMENT CONTROLLER CAN 27 SEE SHEET 8 sheet 13 E
34. Page 30 Ce Lotus Service Notes Section XA XA 13 REMOVEABLE STEERING WHEEL A111H0026J The motorsport removeable steering wheel is a direct replacement for the standard wheel and allows for quick detachment of the wheel for improved cabin access and can provide an increased measure of theft protection The Momo three spoke wheel is the same 320mm 12 in diameter as the standard wheel and is trimmed in red leather with contrasting leather inserts in the thumb areas A removeable key barrel provides the option to lock the wheel to the column and positional variations of the three wheel to hub drive pins ensures that wheels cannot be interchanged between similarly equipped cars Fitting Instructions 1 Remove the standard steering wheel Pull off the centre trim pad with horn button and disconnect the two horn leads Remove the column nut and match mark the hub to the column to aid alignment on re assembly 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 activated necessitating column replacement Dismantle the standard wheel and retain the splined hub and the horn slip ring carrier Assemble the new wheel assembly Fit the horn contact adaptor into the locking ring with the alignment
35. Push pistons to top of their bores Carefully push out each piston assembly taking care that big ends do not contact surface of cylinder liners Refit caps on to connecting rods lightly tighten dowel bolts CAUTION Removal of pistons will necessitate removal and re sealing of cylinder liners OVERHAUL 1 2 3 Piston rings checking Using an expander remove and discard old piston rings Use squared off end of broken piston ring and clean ring grooves Check new ring to groove clearance 12M1785 K8 and 16 1 1 and 1 4 Top compression ring A 0 04 to 0 08 mm 2nd compression ring B 0 03 to 0 062 mm Oil control rails 0 044 to 0 55 mm K16 1 6 and 1 8 Top compression ring A 0 040 to 0 072 mm 2nd compression ring B 0 030 to 0 062 mm Oil control rails C 0 010 to 0 180 mm ENGINE Heese 3496 4 Check new ring fitted gap 20 mm from top of cylinder liner bore CAUTION Ensure rings are kept square to liner bore and that they are suitably identified to the bore in which they are checked and fitted to the piston for that bore K8 and K16 1 1 and 1 4 Top compression ring 0 17 to 0 37 mm 2nd compression ring 0 37 to 0 57 mm O control rails 0 15 to 0 40 mm K16 1 6 and 1 8 Top compression ring 0 20 to 0 35 mm 2nd compression nng 0 28 to 0 48 mm Oil control rails 0 15 to 0 40 mm Pistons inspection Check p
36. The suspension may be disassembled without the use of any special tools other than a spring compressor 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 and the undertray between the lower front edge of the chassis and the front clamshell 1998 02 10 11 12 13 14 8 gt Lotus Service Notes Section Remove the two bolts securing the brake caliper to the hub carrier release the flexible hose from the top wishbone and support the caliper aside without straining the brake hose Remove the brake disc 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 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 Remove the four M10 setscrews securing the lower swivel joint plinth to the hub carrier and withdraw the hub carrier and hub assembly If necessary remove the nut securing the lower swivel joint to the plinth and use a ball joint splitter to separate the forged steel plinth from the joint Remove the bolts securing the spring damper unit to the lower wishbone and chassis anchor bracket and withdraw the uni
37. Using the access provided from the open underside of the rear end of the chassis side rail 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 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 At the rear end of the pipe fit two foam support blocks onto the pipe and push into the chassis rail to expose approximately 35 40 mm of pipe After fitting the hoses manipulate the pipe to check for absence of chassis contact knock Blank off the access hole in the crash structure with a suitable grommet Page 9 Lotus Service Notes Section LH FUEL SYSTEM SECTION LH M111 ELISE Sub Section Page General Description LH 1 3 Fuel Filling LH 2 3 Precautions LH 3 4 Fuel Filter LH 4 4 Fuel Tank LH 5 5 Fuel Pump Sender Assembly LH 6 8 Charcoal Canister LH 7 10 Page 1 Section LH E Lotus Service Notes Leg edid 401289uuoo2 fang AU edid pass Ion jong 40je nB a 1 eJnssaJd 4 dajsiueg S edid ZA jeng 4
38. rear Pressure cold front rear Studding Tyre chains WHEELS Type Std prior April 99 approx VIN 6429 Std from April 99 approx VIN X 6429 1118 amp std option Size front rear std 1115 amp std option PCD Inset front rear std 111S amp std option Wheel nut torque ERONT SUSPENSION Type Geometry check ride height 2 persons tank fuel front rear Alignment Camber Castor Steering axis inclination 2000 02 Michelin Pilot SX GT 185 55 R15 81V 225 45 ZR16 89V 1 6 bar 23 Ib in 1 7 bar 24 5 Ib in Michelin X M S 130 185 55 R15 81T 195 60 R15 88T mounted on standard 15 inch front wheels 1 6 bar 23 Ib in 1 7 bar 24 5 Ib in Not permitted Pewag FX 67 S Ring Super X A100G6011F fitted only on rear winter tyres AWI light alloy 5 split spoke style Rimstock light alloy 12 spoke style O Z light alloy 6 spoke style 5 5J x 15CH H2 ET14 7J x 16H2 ET16 7 5J x 16H2 ET10 95 25 mm 14 mm 16 mm 10 mm 80 85 Independent Upper and lower wishbone axial coil spring telescopic damper unit anti roll bar 140 mm below front end of chassis siderail 140 mm below rear end of chassis siderail 0 2 mm toe out overall 0 0 2 mm 0 03 toe out overall 0 0 03 0 1 0 1 0 2 Max side side 0 2 3 89 0 2 side side 0 2 12 nominal Page 3 E Lotus Service Notes Section TDM REAR
39. 18 Remove camshaft gears OVERHAUL 27 ENGINE 12M0577A 19 Remove screws securing upper part of timing belt rear cover to cylinder head and screw securing rear of cover to coolant pump NOTE This is the longest of the rear cover securing screws 20 Remove timing belt tensioner pillar bolt 21 Using assistance remove cylinder head assembly from cylinder block CAUTION Cylinder head is dowel located do not tap it sideways to free it from cylinder block Place cylinder head assembly on blocks of wood to prevent damaging valves 22 Remove and discard cylinder head gasket 23 Assemble cylinder liner retainer clamps 18G 1736 to cylinder head bolts Position retainer clamps on cylinder liners ensuring clamps do not protrude over liner bores Screw cylinder head bolts into oil rail and tighten sufficiently to retain clamps CAUTION Ensure that bolts used are A those originally fitted in that location 28 OVERHAUL ENGINE Heese Cylinder head 16 non VVC engines fitted with fitted plug top coil ignition system remove NOTE Commencing engine numbers for these engines are listed in Information CAUTION crankshaft is to be removed during overhaul it will be necessary to check and record crankshaft end float prior to removing cylinder head 1 Remove and discard camshaft timing belt CAUTION Do not rotate crankshaft whilst timing belt is removed and cylinder head is fi
40. 1998 03 Page 12 Lotus Service Notes Section REAR SUSPENSION SECTION DE M111 ELISE Sub Section Page General Description DE 1 3 Geometry amp Adjustments DE 2 3 Suspension Disassembly Assembly DE 3 5 Rear Toe Link Fixings DE A 8 Rear Wheel Bearings DE 5 10 Wheel Speed Sensor DE 6 12 Barrel Shaped Road Springs DE 7 12 1098 03 m Lotus Service Notes Section DE Damper clevis Upper ball joint Damper B Top wishbone Hub carrier S2 Rear subframe Lower wishbone Driveshaft Toe control link Road spring Lower ball joint Page 1998 03 Lotus Service Notes Section 1 GENERAL DESCRIPTION The fully independent rear suspension comprises on each side of the upper and lower tubular steel wishbones a toe control link and a concentric coil spring telescopic damper unit picking up on the outboard end of the lower wishbone An extruded aluminium alloy hub carrier houses a dual taper roller bearing which supports the outboard driveshaft and steel hub equipped with 4 wheel studs Onto the LH hub carrier is mounted a wheel speed sensor which operates in conjunction with a sensor ring on the outboard driveshaft in order to supply vehicle speed signal to the speedometer The inboard ends of the upper and lower wishbones use replaceable bonded rubber pivot bushes to provide maintenance free articulation and suppression of noise and vibration The two legs of
41. 7 Disable the ignition low tension and crank the engine to fill the oil cooler and hoses before starting the engine Top up oil level if required Run engine and check for leaks before refitting the topshell Recommended Fitting Time 6 hrs including topshell remove refit Page 40 E Lotus Service Notes Section XA Heat protective Sleeving Oil cooler return hose Oil cooler feed hose Tie strap to water pipe Holes in rad duct inner wall 32mm diameter holes in rad duct outer wall 2000 02 41 Ce Lotus Service Notes Section XA 18 ID E SET LSL398 The Goodridge steel braided brake hose set is a direct replacement for the standard hoses with the following exception The rear hoses do not use the standard P clip on the lower wishbone but should be tie strapped in two places to the rear toe link 19 5TH POIN HARNE IT A34 LSL393 Remove the latch from the seat harness lap strap by inserting a stiff wire into the latch hole By similar technique fit the new rotary release latch to the lap strap Fit the grommet onto the new crutch strap and thread the anchor bar through the crutch strap loop Feed the strap through the seat frame cross brace aperture and the slot in the driver s seat and fit the grommet into the frame aperture Secure the crutch strap anchor bar beneath the seat frame cross brace by the seat front fixing studs Page 42 Lotus Service Notes Section XA
42. D 0 4 mm radius 25 960 to 25 973 mm F 2 1 4 to 1 8mm G 22 83 mm 25 913 to 25 888 mm de 5 45 to 5 80 mm K 2 5 7 to 5 86 mm ENGINE fesse K16 VVC engines fitted with triple angle valve seats See illustration M12 5536 Inlet Ais 15 45 60 D 0 4 mm radius E 32 560 to 32 573 mm F 1 0 to 1 4 mm G 30 2 mm H 32 475 to 32 500 mm J 5 95 to 6 00 mm K 6 1mm Exhaust 15 45 C 60 D 0 4 mm radius E 28 993 to 29 006 mm F z 1 4 1 8 mm G z 26 23 mm H 28 888 to 28 913 mm J 5 45 to 5 50 mm K 6 54 mm All engines 1 Cut valve seat to correct angle and width 2 Lap valve to seat OVERHAUL 55 ENGINE Valve seats refacing CAUTION Renew worn valve guides before refacing valves and seats 1 Check condition of valve seats and existing valves that are to be re used 8RM 3530B NOTE Triple angle valve seat illustrated 2 Recut valve seats and use pilot MS120 6 and the following cutters MS76 120 15 Triple angle valve seats only 76 111 60 To narrow valve seats and obtain seat widths MS76 122 45 Make final cut and remove any burrs Valve seat Angle 45 Width A Except triple angle valve seats Inlet 1 5mm Exhaust 1 5mm Triple angle valve seats Inlet 1 0 to 1 4 mm Exhaust 1 4 to 1 8 mm Valve face angle B Inlet 45 Exhaust 45 CAUTION Inserts must not s
43. Orr STEERING SECTION M111 ELISE Sub Section Page General Description HE 1 2 Steering Wheel HE 2 2 Upper Column Assembly HE 3 4 Intermediate Column HE 4 7 Front Wheel Alignment amp Rack Gaiters HE 5 8 Rack amp Pinion Assembly Removal Replacement HE 6 9 Adjustment of Rack Bar Thrust Pad HE 7 10 Page 1 Lotus Service Notes Section HE Upper column Upper column assembly mountings Track rod end Intermediate column Rack mounting Thrust pad adjuster Rack housing Gaiter Track rod HE 1 GENERAL DESCRIPTION The steering system of the Elise comprises a telescopically collapsible upper column assembly connect ing 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 extruded alloy front hub carriers with geometry providing 30 Ackermann effect and a toe out on bump characteristic No power assistance is provided 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 HE 2 S
44. Thick If two bearing colours are to be used thicker bearing must be fitted to big end bearing cap 86 OVERHAUL ENGINE 2299 Crankshaft and big end bearings refit 1 Clean sealant surfaces on block bearing ladder and oil rail Use foam action gasket remover and a plastic scraper DO NOT USE A METAL SCRAPER ON SEALING SURFACES Ensure oilways are clear Examine shoulder location on each big end bolt renew if damaged Check that core plug at each end of oil rail is in good condition renew as necessary 5 Clean sealing surfaces on cylinder block and bearing ladder using suitable solvent 1201780 6 Apply a continuous bead of sealant Part Number GUG 705963GM to paths shown on cylinder block then spread to an even film using a roller CAUTION To avoid contamination assembly should be completed 1201779 immediately after application of sealant 2 Fit selected main bearing shells into cylinder block and bearing ladder as indicated in the table 3 Fit thrust washers into block each side ol Number 3 main bearing with oil grooves facing outwards 4 Lubricate crankshaft main journals with engine oil Hold crankshaft with big end joumals horizontal and using assistance lower crankshaft on to main bearings OVERHAUL 87 ENGINE 7 Lubricate main joumals with engine oil Fit bearing ladder to block fit bolts ensuring that flanged head bolt is fitted at position 10
45. VVC engines Blue 3 Use a wooden dowel and mallet lightly tap top of each valve assembly two or three times to seat valves and collets 4 Lubricate outside of tappets and fit tappets in original bores ENGINE 99221 Camshafts 8 and all K16 Non VVC engines refit 1 Lubricate bearings and fit camshaft s and position drive pin for 90 BTDC as follows K8 Pin at 4 o clock K16 Inlet pin at 4 o clock Exhaust pin at 8 o clock Camshaft carrier and oil seal K8 engines refit 1 1 ANNE i Cos ao AY 1 Ensure 2 locating dowels are fitted in camshaft carrier 2 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on camshaft carrier as shown and spread to an even film using a roller CAUTION Ensure sealant does not enter lubrication grooves on camshaft carrier and that assembly is completed within 20 minutes 3 Lubricate camshaft cams and journals with engine oil 12M0563 4 Fit camshaft carrier fit and lightly tighten bolts using sequence shown 5 Tighten all bolts in sequence shown to 10 Nm OVERHAUL 61 ENGINE 18G1769A 12 0564 NOTE Camshaft front seal illustrated N 6 Fit oil seal protector 18G 1749 over end of camshaft 7 Fit new camshaft oil seals using tool 18G 1769A NOTE Front oil seals are coloured 2 BLACK rear oil seals coloured RED CAUTION Oil seal
46. 0 01 0 04 mm 80 000 80 015 mm 80 016 80 030 mm EECHER annn 19 Paae 3 E Lotus Service Notes Section TDL IL PUMP Outer rotor to housing clearance 0 28 0 36 mm Inner rotor tip clearance 0 05 0 13 mm Rotor end float 0 02 0 06 mm COOLANT THERMOSTAT Nominal setting 85 91 C Thermostat starts opening 88 C Thermostat fully open 100 C Page 4 Lotus Service Notes Section TDM M111 Dimensions e zer a e ai aas 2 CRC TNS E eae eE PA EANES 2 RC ca EE 2 Winter 22 Pese a Iv PE FAR HT v 3 3 FFOREASUSDENSION estate rex a eee uu 3 Rear SUSPENSION 4 Electrical eae IAS 4 TRANSMISSION EM 4 dece AD eter e e dene e Fe de Doe uenis cra ode pao Eo EY 5 ICI MM 5 SIBerl A Dea ERA 5 Fuel CONSUMPTION Kex EXE dte 5 2000 02 1 E Lotus Service Notes Section TDM DIMENSIONS Overall length std 111 Overall width exc mirrors std 1115 inc mirrors Overall height at kerb weight Wheelbase Track front rear std 1115 Ground clearance Front overhang Rear overhang std 1115 Approach angle Departu
47. 1389 000 1390 Churchill Part No ref 18G1578 18G 2 3 18G 134 18G 134 4 18G 284 18G 284 14 18G 1354 18G 1354 5 18G 1392 18G 1397 18G 1472 18G 1473 18G 1675 18G 1723 1 18G 1723 2 18G1483 18G1354 16 18G134 12 Page 11 Service Record NTENANCE SERVICE DUE AL PG1 Manual Gearbox Overhaul Manual PG1 Handgeschakelde versnellingsbak revisiehandboek PG1 Bo te de vitesses manuelle TW Manuelder vision PG1 Schaltgetriebe Uberholungsanleitung PG1 Cambio meccanico Manuale direvisione PGI Caja de cambios manual Manualderevisi n PGI Caixa de velocidades manual Manualde revis o RCL 0124 PG1 MANUAL _ GEARBOX OVERHAUL MANUAL This gearbox is fitted to the following models Rover 218 418 Diesel New Rover 200 Diesel New Rover 218 New Rover 400 Diesel Rover 220 Rover 420 Rover 600 Diesel Rover 600 Ti Rover 820 Rover 800 KV6 MG F Publication Part No RCL 0124 ENG 2nd edition Published by Rover Technical Communication 1997 ROVER GROUP LIMITED INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub section is given at the bottom of each page This manual contains procedures for the overhaul of the gearbox on the bench with the engine removed For all other information regarding General Information Adjustments Removal of oil seals gearbox unit consult t
48. 16K4FL32 6847 5 16K4FL33 684141 16K4FL34 6748 16K4FL35 675041 18K4FJ31 685002 18K4FJ32 678009 18K4FJ78 679210 18K4FJ79 682294 18K4FL66 658261 18K4FL67 615758 18K4KL36 667388 18K4KL37 657611 18K4KJ89 673981 18K4KJ90 637368 Modified type B crankshafts 11K2FK42 602582 14K2FH67 601998 14K2FK43 604022 14K2FK44 585572 14K2FL64 589869 14K4FH71 589479 14K4FH72 603771 14K4FK76 580134 14K4FK77 602717 16K4FH75 597254 16K4FH76 597902 16K4FK79 581514 16K4FK80 583009 16K4FK88 605066 16K4FK89 600785 18K4FJ31 599800 18K4FJ32 577734 18K4FJ79 581514 18K4FJ89 597466 18K4FK61 547750 18K4FK67 526547 18K4FK68 323456 18K4FL50 527882 18F4FL51 551737 18K4FL82 589737 18K4KH77 585941 18K4KH78 588402 18K4KJ90 568275 INTRODUCTION 3 ENGINE This page is intentionally left blank l a SSS A SES DESCRIPTION AND OPERATION 1 INE 12M1757A DESCRIPTION AND OPERATION ENGINE This page is intentionally left blank DESCRIPTION AND OPERATION 1 IGINE 12M1757A DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS COON OO AWN Oil pump assembly Gasket oil pump Screw M6 x 30 oil pump Screw M6 x 20 oil pump Crankshaft front oil seal Dipstick Dipstick tube Screw dipstick tube and thermostat housing Screw dipstick tube Gasket Coolant pump O ring coolant pump Pillar bolt if f
49. 22 Input Shaft End thrust Check and Adjust 24 Differential Pinion Gear Backlash Check and 61 25 Differential Bearing Pre load Check and 26 GEARBOX ASSEMBLING 27 DATA TORQUE amp TOOLS pru E 1 TORQUE SETTINGS tease oed oe ee edu 2 te e 2 MANUAL GEARBOX This page is intentionally left blank DESCRIPTION AND OPERATION 1 NUAL GEARBOX 37M1297 DESCRIPTION AND OPERATION REVISED MANUAL GEARBOX 0 0 Needle roller bearing 2nd gear 2nd gear 9rd gear 4th gear bth gear Ball bearing output shaft Ball bearing output shaft Tongued washer Output shaft nut L H thread Circlip Reverse idler shaft Thrust washer reverse idler gear Roll pin reverse idler shaft Reverse idler gear Reverse selector fork Oil seal input shaft Ball bearing input shaft Input shaft Needle roller bearing 3rd gear 3rd gear Synchro ring 3rd gear Synchro spring Synchro hub 3rd 4th gears Synchro sleeve 3rd 4th gears Synchro spring Synchro ring 4th gear 4th gear Needle roller bearing 4th gea
50. 8 captive fixings in the screen frame buttresses The front pair use M8 captive fixings in the radiator mounting panel Take note of the shim stacks fitted at each of the fixing points 6 Remove the five screws securing the front lower edge of the clamshell to the front alloy undershield 7 Disconnect the clamshell wiring harness at the driver s side of the front compartment and lift the clamshell from the car Note any spacing washers or shims fitted at any fixing point Page 7 Eb Lotus Service Notes Section BN Front Clamshell Fixings Windscreen buttress Radiator duct Front undertray A post top Sill front end A post bottom 221 8 Refit the clamshell in reverse order to removal taking care to retain any spacer washers their original positions BN 5 REAR CLAMSHELL The rear clamshell is a one piece composite moulding incorporating both rear wings the engine bay aperture and rear lamp assemblies A flat alloy shear plate is bonded into each side of the moulding in order to stiffen the panel and provide a mounting point to the chassis 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 Iffitted remove the roll bar fairing and rear window 2 Remove both rear roadwheels 3 Remove the fixings securing both rear wheelarch liners Two fixings at the front edge of the liner into the
51. 98 VIN X 5401 5450 6001 6035 135 bhp cylinder head Close ratio gearbox Sports exhaust Competition style seats Sports steering wheel Drilled iron brake discs Quicksilver paint with blue soft top Headlamp covers Body graphics Silver roll over bar 2nd batch variations 111S wheels tyres amp spats black painted fuel filler cap matt finish alloy gear knob Sport 135 99 side decals Integral Stud Toe Link Ball Joints December 98 VIN X 5479 Rear suspension toe link ball joint design changes to incorporate integral M10 stud 50th Anniversary Elise January 99 VIN X 5463 5816 total 51 Anniversary green with gold wheels green rafia leather seats Elise floor mats gold decals Anniversary decal on rear transom Angled Rear Window January 99 VIN X 5558 Rear window mounted in angled surround to reduce reflections Elise 111S January 99 VIN X 5722 VVC engine amp close ratio transmission Revised muffler amp tailpipes Cross drilled iron discs Lotus styled 6 spoke road wheels 7 5 rear rims with 225 45 ZR16 rear P Zeros Optional rear spoiler extension Acrylic headlamp covers amp smoke front indicator lenses Composite engine lid rear wheelarch spats 111S decal on rear body amp fascia moulded air intake grille Forged alloy window winders weave patterned dash inserts revised seat foams amp stitching Elise JPS July 99 Available based on either standard or 111S versions Black bo
52. Assemble cylinder retainer clamps 18G 1736 to cylinder head bolts Position retainer clamps on cylinder liners ensuring that clamps do not protrude over liner bores Screw cylinder head bolts into oil rail and tighten sufficiently to retain clamps CAUTION Ensure that bolts used are AN those originally fitted in that location 34 OVERHAUL ENGINE Camshafts K8 and all 16 Non VVC engines Camshafts K16 VVC engines check end float check end float Inlet camshafts 1 Check end float of each camshaft using DTI D Camshaft end float 0 06 to 0 19 mm Service limit 0 3 mm L 2 2 Renew components as necessary to achieve correct end float 12M3493 1 Assemble a suitable DTi to camshaft carrier with stylus of gauge contacting face of front camshaft number 4 cam 2 Move camshaft fully rearwards and zero gauge 3 Move camshaft fully forwards and note end float reading on gauge Inlet camshaft end float 0 03 to 0 15 mm Service limit 0 25 mm 4 Repeat above procedure for rear camshaft with stylus of gauge contacting face of number 5 cam 5 Renew camshaft VVC assemblies as necessary to achieve correct end float OVERHAUL 35 ENGINE Exhaust camshaft 6 Check camshaft end float using a DTI Exhaust camshaft end float 0 06 to 0 19 mm Service limit z 0 3 mm 7 Renew components as necessary to achieve correct end float Camshaft carrier and camshafts K8 and all
53. Do NOT attempt to remove the inboard C V joint from the transmission by pulling on the driveshaft This action will cause the joint to become disassembled and may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive axial force is used Apply pressure only to the tulip or outer body of the joint Withdraw the inboard joint from the transmission and fit blanking plug T000T1385 into the transmis sion to limit the amount of transmission oil loss 6 Remove the four M10 setscrews securing the lower swivel joint plinth to the hub carrier disconnect the speed sensor harness LH hub and withdraw the hub carrier hub and driveshaft assembly 7 Remove the top wishbone pivot bolts and withdraw the wishbone from the rear subframe 8 Remove the top and bottom mounting bolts for the spring damper unit and withdraw 9 Remove the lower wishbone pivot bolts and withdraw the lower wishbone and toe link 10 If necessary remove the top or bottom swivel joint ball pin nut and use ball joint splitter tool to separate the joint from its plinth The swivel joint may be replaced using suitable press tool dollies 11 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 cha
54. E Lotus Service Notes Section MN ELECTRICS SECTION MN M111 ELISE Sub Section Page Vehicle Security Alarm Standard Lucas amp Cobra 6019HF option MN 1 2 Lotus Check Scanner Tool MN 2 7 Switches amp Instruments Driver s Information MN 3 9 Component Location amp Fuse Ratings prior Oct 97 MN 4 15 Audio Equipment MN 5 17 Battery Battery Cables amp Earthing Points MN 6 18 Wiper Mechanism MN 7 21 Fitment of Driving Lamps MN 8 22 Harness Routing MN 9 23 introduction of Uprated Starter Motor MN 10 28 Circuit Diagrams prior to Oct 97 white paper MN 11 29 Vehicle Security Alarm Cobra 6422 option MN 12 31 Fuses amp Relays Oct 97 onwards MN 13 36 Circuit Diagrams Oct 97 onwards cream paper MN 14 37 Page 1 Lotus Service Notes Section MN MN 1 VEHICLE SECURITY ALARM Standard Lucas amp Cobra 6019HF option Prior to October 97 Elise models may be equipped with one of two levels of alarm system The base system uses a Lucas 5AS module which is electronically matched to the engine management ECM to provide a passive immobiliser function and operates the vehicle horn if either door is opened or the ignition circuit energised Cars with this level of alarm may be identified by the Lucas branded transmitter keys Standard Upgraded alarm alarm transmitter transmitter key key The optional factory alarm upgrade uses a Cobra Goldline 6019HF system which incorporates passive immobilis
55. Engine mounted water rails Oil filter Ignition coil spark plugs and harness Engine Fitting Kit The additional parts required in order to fit the VHPD engine are contained in fitting kit A111E0034J and comprise Carbon fibre cold air box and trunking Requires removal of boot bulkhead to accommodate the air box and cutting down of the standard air filter mounting plate for the trunking The charcoal canister also requires removal with a corresponding modification to the filler neck breather hose routing New throttle cable New fuel feed and return pipes with clips Crankcase breather pipe kit Throttle cable U bracket Cobra immobiliser bridging plug Unless already so equipped the later type closer finned 20 f p i instead of 16 f p i engine cooling radiator must also be ordered and fitted 111 0021 Additional parts strongly recommended in order fully to exploit the performance of the VHPD engine it is strongly recommended to fit the following components Oil cooler kit 111 00375 Competition silencer kit A111S0037S and catalytic converter substitution pipe A111S0048S 2000 03 G 1 2 Lotus Service Notes uidance notes for fitting engine assembl Section Remove complete power unit as detailed Elise Service Notes sub section EE 3 Remove the transmission and clutch sub section QF 4 The standard friction plate and clutch cover can b
56. Lotus Service Notes Exige The Exige alloy chassis tub composite front crash structure steel roll over bar and steel rear subframe are all unchanged from standard Elise but the earlier type of boot floor arrangement is used with an alloy fioor panel rivetted between the rear longerons BODY The Exige uses standard Elise body side sills windscreen frame and door shells and a rear bulkhead different only in captive fixings The front services compartment lid is also common with Elise The bolt on front and rear clamshells are specific to Exige and are similar in styling to the motorsport series cars The rear tailgate is a clear polycarbonate moulding bonded to a composite reinforcing frame with intake and outlet air ducts incorporated into a spine feature A single top mounted hinge is used together with a new cable operated latch mechanism The roof panel incorporates an air intake duct for the engine bay and although retained by the same fixings as are used on the Elise hardtop the car should not be driven with the roof panel and tailgate removed Mounted on the rear body deck by two moulded plinths is a new motorsport style aerofoil with integral endplates which transfers loads into the chassis via rear clamshell support plates The rear aerofoil and front splitter panel combine to provide balanced aerodynamic forces for optimum high speed handling The front clamshell is secured by threaded fasteners in a s
57. New joints are pre packed with grease but if re fitting a cleaned out joint lubricate the joint with one sachet of the special grease provided in the boot kit Fill the ball tracks with grease both behind and in front of the balls pack around the balls and the inside of the splines so that grease is pushed behind the joint when the shaft is inserted Use the second grease sachet from the boot kit to fill Page 9 10 11 12 Kon Lotus Service Notes _ Lotus Service Notes Section FH the inside of the new boot NOTE The grease provided in the kits is specially formulated for wear resistance and durability DO NOT use substitutes or mix with other lubricants Inboard Joint If re fitting a cleaned out joint pack the joint with two of the grease sachets from the gaiter kit Use the third grease sachet from the gaiter kit to fill the inside of the new gaiter Slide the outer joint onto the shaft splines and tap the joint into position until the circlip clicks into its groove Pull on the joint to ensure it is fully located Pull each gaiter over its C V joint and locate the lips of the gaiter in the grooves on the joint and shaft Before fitting the gaiter clamps ensure that the gaiter is ventilated so that it is not dimpled or collapsed Position the plunging joint with 80 mm between the boot clip grooves before ventilating by inserting a smooth rod take care not to damage the boot between the large en
58. SHEET 8 INSTR PACK C SEE SHEET 14 SPLICEC HORN RELAY 4 d rdi Lo lj Page 39 2000 03 IOE E INTERIOR FAN CIR i 2000 03 E Lotus Service Notes Exige RI The service interval for standard Elise and Elise 111S models is 9 000 miles 15 000 km For 340R Sport 160 and Exige models the interval is 6 000 miles 10 000 km Maintenance Schedule LSL348 has been updated to D level to include the Exige IGE P IN TION As standard Elise iG H T As standard Elise 2000 03 ich
59. 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 If the reservoir needs topping up first clean around the cap to reduce the possibility of contamination before unscrewing the cap itis 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 DOT 4 non mineral type fluid identified by a yellow and black symbol 1146 1998 03 i Lotus Service Notes Section JH 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 neces sary to remove some fluid using a squeeze bulb type tool Renewal of Brake Fluid Brake fluid aborbs water from the atmosphere over a period of time hygroscopic resulting in a lowering of the boiling point of the fluid and corrosion of the hydraulic system For optimum safety and brake performance the br
60. The wiper is controlled by the up down position of the lever switch which operates as follows Moved fully down the wiper is switched off cor 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 op gt eration Move fully upwards for quick wipe to be used only in heavy rain Washer 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 ste xjng wheel interior Lamp An interior lamp is mounted centrally in the lower section of the dash and is equipped with a three position switch Switch forwards lamp is switched on with or without ignition Switch central lamp is switched off Switch rearwards a driver s courtesy mode applies where the lamp is switched on whenever the driver s door is opened and goes out when the door is closed Note that the lamp is not operated from the passenger door whose sensing switch is used only for the alarm system Inertia Switch The safety inertia switch is designed to oper ate on impact such as will occur in an accident to switch off the fuel pump and thus mini
61. U end to frame Washer M12 Corner Plate bracing strut to floor RHD LHD Reinforcing Plate corner plate to floor Screw M8 x 20 pan pozi corner plate to floor Washer M8 S Nut M8 ig E Setscrew 8 x 16 corner plate to chassis side rail Washer M8 Nut M8 Grommet chassis side rail access hole Fitting Procedure 1 If fitted remove the following Roll bar fairing and rear window Both audio speaker panels Both inertia reel lap and diagonal seat belts Passenger footrest Part Number A111A0245S A111A0246S A111A0234S A111W2183F A075W4029F A111A0224S A075W2059Z A075W4037Z A079W1044F A075W4079F A907E6284F A111A0239S A111A0226 7 A082W2157F A082W4154F A111A0237 8S A111A0244S A075W5095F 075 4079 907 6284 A075W1036Z A075W4079F A907E6284F A111A6003F Qty 1 SA NMNNNNNNH HH HHH FPRRNMNNNNDND 2 Remove the end spigots from the frame harness bar and fit the frame into position Locate each bottom end of the frame with a hex head bolt and washer to the existing inertia reel fixing point 3 Insert the end spigots into each end of the harness bar and fit the fixing bolts to the roll hoop and harness bar Tighten the A frame bottom fixings to 38 Nm the harness bar end spigots to roll hoop to 45 Nm and the harness bar to end spigot through bolts to 22 Nm 4 Remove the nut and washer from the passenger side front lower wishbone rearmost pi
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63. and face level vents Each of the wind screen outlet vents may be manually rotated and directed as required To boost airflow from the windscreen and footwell vents close off the face level vents using their individual thumbwheels Footwell and screen solenoids energised vacuum opens footwell flap vacuum shut off from screen flap which opens Windscreen At this position airflow is directed to the wind screen and face level vents Each of the wind screen outlet vents may be manually rotated and directed as required For maximum defrost performance select full heat and fan speed and close off the face level vents using their individual thumbwheels Turn the screen vent vanes to align with the screen and open to about 45 angle to aim at the glass Screen solenoid energised vacuum shut off from screen flap which opens Page 8 Airflow from face level Face level gt if required en Airflow to windscreen 2000 04 Lotus Service Notes Secten PH Lotus Service Notes Section PH PH 3 VACUUM CONTROL SYSTEM Engine vacuum tapped from the intake plenum is used to operate the screen footwell and re circ flaps and the water valve The vacuum supply to each of the actuators is controlled by separate solenoid valves mounted on a bracket above the pedal box with the solenoids switched by the climate distribution control In order to maintain flap operation during periods of high manifold pre
64. and position the pointer just above the index wire Continue with operation 7 10 Refit the belt guards t cement Pipe 0 4 hr Remove the catalytic converter and replace with the cat replacement pipe ther Kit amp Catch Ta 6 br Fit the breather catch tank to the LH side of the engine bulkhead Remove the breather hose between the cam cover and airbox and fit the grommet to the airbox hole Remove the breather hose from the cam cover to breather rail Use the breather hose kit to connect the two cam cover breather spigots to the catch tank Leave the other breather catch tank vent pipe free or fit a Pipercross vent filter Remove the steel breather rail from the inlet tracts and fit the alloy blanking plugs to the inlet tract spigots Delete Charcoal Canister 0 2 hr Remove the charcoal canister and plumbing Vent the fuel tank breather pipe from the roll over valve to atmosphere Lower Temperature Thermostat 0 7 hr Replace the standard 88 thermostat with the 82 item HD Only Qil Cooler Kit 5 hr Note that all LHD cars were factory built with oil coolers For RHD oil cooler fitting procedure see XA 17 or LSL388 nded for road D AC 4 hr Remove the idle air control valve mounting bracket and plumbing Fit the blanking plugs to the inlet tract spigots on manifold underside Fit blanking grommet to backplate Saves 667g On road based cars for further performance enhancement between 5 000 and 6 500rpm and wit
65. and tighten until sheared HE 4 INTERMEDIATE COLUMN Instrument cowl Instrument pack Instrument amp cowl mounting bracket The intermediate steering column consists of a symmetrical splined shaft and two different hookes type universal joints The lower joint uses an un indexed 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 at each end and an indexed pinch bolt groove Page 7 Lotus Service Notes Section HE To remove the intermediate column assembly the upper column must first be removed see sub section HE 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 HE 5 TRACK ROD ENDS amp 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 Ackerman a
66. gt i Bt HOLIMS 1738 1935 5 SE Du z gt dt et S 2 4866 ANY 71303 d Y 14305 H a S e 280584365 BE 09 99 8 a 8 a se a E GN es i ou 4 GE Ces LLI ike 4 oe Zei W RE m gel yy na no gt o 2 J 5 9 m de ce TEE 2 G H y ye Sem ID Nl e u an NA 2 2 ii E 24056 199 10 Z 5 aeu i D LS E ONINYYM lete Wass Sa gt Wv38 Niven 25 Md Ee 2n FAL HOLIMS NOLIVNLNQ TY TINY4 DS gt 8 d NE a b m 2056 da E Ss p RS 5 4 pv 5 is 5 xS EE CO NER P bd E T ae 3 5 S 5 a 8 5 T Wir Y 6 N24 z E i Mes 5 GC Oa E Lotus Service Notes Section MN WINDSCREEN WIPERS BATTERY IGNITION ISTART DROP OUT IGNITION tUNFUSED gt IGNITION FUSED D 6 E GK EN m WIPER MOTOR iN TERMITTANT WiPE MODULE 1 A N l La _ SLREL NWASH PUMP gt uf H ct Di SHEET II Lotus Service
67. oil all over the element then gently massage the oil into the depth of the foam IMPORTANT If the filter is not oiled thoroughly some fine dust may work through the filter Page 7 E Lotus Service Notes Section XA XA 3 COMPETITION COMPETITION STYLE SEATS amp 6 POINT COMPETITION HARNESS The Competition Seat is made by Corbeau specifically for the Elise for race track use and features prominent shoulder wings and raised side bolsters designed to provide maximum lateral support in racing conditions Four point multi position mounting brackets connect the seat to new seat mounting rails which use the original chassis fixing holes A wide range of seat position height and tilt is available but once chosen is not readily adjustable Note that the seat needs to be angled towards the car centreline as does the standard seat and uses different fixing holes in the inboard and outboard rails The seat and mounting rails are de signed for use with the 6 Point Competition Seat Beit Harness in conjunction with the Roll Over Bar Reinforce ment Kit Only one Competition seat can be fitted as a similar passenger seat would result in a clash between the seat back wings However a Competition Style passenger seat is available which uses the standard seat shell trimmed to match the Competition seat and modified to allow fitment of the competition seat belt har ness Alternatively a pair of Competition Style seats may be fitted using eith
68. only in conjunction with the headlamps When the Switch is pressed the integral tell tale brightens only if the headlamp switch is also pressed and the fog circuit is operating Press the switch a second time to switch off In some territories rear fog lamps may be used le gally only in conditions of seriously reduced visibil ity Be aware that indiscriminate or forgetful use of the rear fog lamp can cause distraction and discom fort to following traffic Master lighting Hazard lamps On some cars as a legal requirement the rear fog lamp circuit is designed to switch off automatically whenever either the headlamps or the ignition is next turned off regardless of the rear fog switch position In order to reactivate the rear fog lamp the switch must first be pressed off before pressing on once again The Switch tell tale lights up only when the fog lamp circuit is operating Page 12 Lotus Service Notes Hazard Warning Lamps Switch Section MN A red tell tale in the switch button is back lit when the sidelamps are switched on in order to help locate the switch The switch is operative at all times and when pressed flashes all the turn indicator lamps and the Switch tell tale in unison This facility should be used when the vehicle has to be stopped on the highway in abnormal circum stances where a warning to other traffic would be prudent Use of the hazard warning lamps may be subject to local traffic
69. plenum to the new lower manifold with gasket and screws Fit the throttle body assembly to the new plenum Fit the air inlet temperature sensor with its new adaptor into no 4 branch of the new lower manifold Fit the new blanking vac spigot plate with gasket to the end of the new intake plenum Fit the fuel rail assembly and injectors into the new lower inlet manifold Fit the new fuel return pipe to the fuel rail Assemble the new cylinder head Fit the cam belt top cover Fit the camshaft pulleys Fit the two new inlet manifold studs into the top two fixing holes in the head Fit the five new exhaust manifold studs Fit the distributor cap and leads Fit the timing pedastal bolt Fit the water outlet elbow and gasket Fit the new inlet manifold assembly Fit the new cylinder head assembly as detailed in service notes section EE paying attention to the crank shaft and cam positioning to avoid piston valve foul Fit the new manifold support strut to the manifold and cylinder block using the new bolts supplied Connect the fuel pressure regulator valve sensing hose and MAP hose to the right hand end of the intake plenum the two spigots or single spigot and T piece Fit the exhaust manifold With camshaft cover removed pour oil over the camshafts and valve gear to ensure adequate lubrication on start up Fit cam cover and new spark plug cover If applicable fit the new aluminium boot bul
70. the new U K built version d U K built Lotus approved rear tyres are available under part number A111G6022H DOT code is moulded on the outside wall with only the last number group relevant to this issue Note thatthe three digits represent a date code as explained above and not an ordinary sequential number amp Pirelli Zero 225 45 rear tyres There are variations in the specification of this Pirelli tyre dependent on when it was manufactured For the Elise use only tyres with a DOT date code of week 35 of year 98 coded as 358 or later Alternative Service Fitment As an alternative to Pirelli tyres a complete vehicle set of Michelin Pilot SX GT tyres may be fitted in service using the wider rear tyre specification Type Michelin Pilot SX GT Size front 185 55 R15 81V Lotus part no A111G6020H rear 225 45 ZR16 89V Lotus part no A111G6021H Pressure cold front 1 6 bar 23 Ib in rear 1 7 bar 24 5 Ib in It is not recommended to mix Pirelli and Michelin tyres the same vehicle 1999 03 Page 3 E Lotus Service Notes Section GF 2 WINTER TYRES amp SNOW CHAINS the car is to be used in very cold territories or driven on snow covered roads it is recommended to fit winter tyres developed specifically for such conditions Lotus approves the fitment of Michelin M S 130 winter tyres in the following sizes Type Michelin X M S 130 Size front 185 55 R15 81T mounted on standard
71. 15 inch front wheels rear 195 60 R15 88T mounted on standard 15 inch front wheels Pressure cold front 1 6 bar 23 Ib in rear 1 7 bar 24 5 Ib in Note that the rear winter tyres are to be mounted on standard 15 inch front wheels rather than the standard 16 inch rear wheels 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 Tyre Chains Snow chains may by used in extreme conditions only in conjunction with winter tyres see above and fitted only on the rear wheels Lotus approves the fitment of Pewag FX 67 S Ring Super X snow chains available under Lotus part number A100G6011F Close attention should be paid to the fitting and tensioning instructions supplied with the chains and an appropriate driving style adopted The chains should be removed as soon as road conditions allow EMERGENCY PUN TYRE INFLAT In order to fully exploit the benefits of light weight and to maximise stowage space and convenience a keen you mobile punctured tyre inflator aerosol is stowed in the front services 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 neares
72. 16 K16 engines fitted with automatic timing belt tensioner Fit new camshaft timing belt 1 Clean mating surfaces and inside of camshaft cover necessary wash oil separator element in suitable solvent and blow dry 2 Fit new camshaft cover gasket dry to camshaft carrier with either TOP mark towards the inlet manifold or EXHAUST MAN SIDE towards exhaust manifold M124976 3 Fit camshaft cover on to camshaft carrier fit bolts and tighten in sequence shown to 10 Nm 4 Lubricate a new O ring with engine and fit to camshaft sensor 5 Fit camshaft sensor fit bolt and tighten to 5 Nm 6 Secure harness to clips on camshaft cover 7 Fit spark plug cover fit screws and tighten to 10 Nm NOTE Short screw is fitted in centre of ES cover 8 Position timing belt upper rear cover to cylinder head fit screws and tighten to 9 Nm NOTE Longest screw secures cover to A coolant pump OVERHAUL 75 ENGINE 12 182 M12 4977A 9 Fit camshaft gears to their respective camshafts ensuring that drive gear pins are located in correct slot in drive gears hold gears using tool 12 182 fit and tighten bolts to 65 Nm 12 182 18G 1570 M12 4975 10 Using tool 12 182 align camshaft gear timing marks 11 Fit camshaft gear locking too 186 1570 12 Fit new camshaft timing belt NOTE Timing belt tensioner is fitted when timing belt is fit
73. 3 4 of a turn after the filter sealing ring has made con tact Start the engine and check for oil leaks Sump drain plug Re check the security of the filter further tight ening by hand if necessary Check the oil level see above when the engine is fully warm Used Engine Oil WARNING Prolonged and repeated contact with used engine oil may cause serious skin disorders including dermatitis and cancer Avoid contact with skin as far as possible and wash thoroughly after any contact Keep out of reach of children PROTECT THE ENVIRONMENT It is illegal to pollute drains water courses and soil Use authorised waste collection facilities including civic amenity sites and garages providing facilities for disposal of used oil and used oil filters If in doubt contact your local authority for advice on disposal Severe Service Conditions Certain operating conditions can cause rapid degradation of the oil quality either by the accumulation of dirt particles or by the absorption of water from condensation If either of the severe service conditions described below apply it is recommended that the oil and filter be changed twice as frequently as is listed in the Maintenance Schedule Change the oil and filter as soon as possible after driving in a dust storm Driving in dusty areas e g unmetalled roads X Stop start city driving with frequent short trips where the engine rarely warms up thoroughly especially
74. 30 minutes 3 Check rack teeth for signs of wear or damage replace hydraulic control unit if either are evident 4 Check control shaft teeth for signs of wear or damage replace control shaft if either are evident 5 Check that oil passages in spool valve are Clear Hydraulic control unit 16 VVC engines assembling CAUTION It is essential to ensure that absolute cleanliness is maintained during the following operations 1 Thoroughly clean all components dry with compressed air 2 Lubricate new labyrinth seals and rack seal with engine oil 12M3522A 3 Using the fingers only fit labyrinth seals each side of hydraulic control unit seal plate CAUTION Ensure seals are located beneath retaining lugs 4 Fit new rack seal to plate 12M3532B 5 Slide piston end of rack through seal CAUTION Only insert rack through seal for a sufficient distance to enable piston to be fitted and take great care that teeth of rack do not contact seal 6 Secure rack in a soft jawed vice fit new piston and seal assembly to rack fit and tighten new screw supplied with seal kit to 9 Nm 7 Lubricate piston bore with engine oil 8 Position seal plate piston and rack assembly to hydraulic control unit with rack teeth facing towards fixing hole adjacent to solenoid side of unit 12M3658A 9 Insert piston and rack assembly into bore of housing at an angle as shown taking care not to damage piston seal
75. 34 litres Displays actual fuel quantity 35 Display reads Ful COD Cispiay panel order to ensure the vehicle is not stranded and to protect against the potentially damaging effects of fuel starvation it is strongly recommended to refuel at the first opportunity after Refill is displayed 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 40 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 SH Page 11 Lotus Service Notes Section MN the cooling fan switching on at approximately 104 C The display will flash at temperatures over 100 Cin order to prompt closer monitoring of high ternperatures 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 After a heavy snowfall ensure that the radiator cooling outlet grilles in the front bonnet 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 c
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77. 5A Re circ pump air con only battery services 20 20 Fast fan speed relay 9 10A Hazard lamps 21 10 7 5A Horn 22 11 10A Alarm amp Int lamp Relays A Horn C Dip beam B Cooling fan D Main beam Page 36 CSS Lotus Service Notes Section MN MN 14 CIRCUIT DIAGRAMS Oct 97 onwards Circuit Sheet Start Alternator amp Ignition 1 Fuel Pump amp Cooling Fan 2 Engine Management System 3 Alarm amp Immobiliser Lucas 4 Alarm amp Immobiliser Cobra 6422 5A Stop amp Reverse Lamps 6 Direction Indicators amp Hazard Lamps 7 Headlamps 8 Sidelamps amp Fog Lamps 9 Instruments 10 Windscreen Wipers 11 Interior Fan 12 Radio amp Cigar Lighter 13 Power amp Ground Structure 14 Inter Harness Connectors 15 Fuses 16 Hot Soak Pump A C Cars 17 Cooling Fan Relay 2 A C Cars 18 Interior Fan A C Cars 19 Solenoid Valve Control A C Cars 20 A C Request amp Control Non Heater 22 peu 22 2 2 2 22 22 EE EECHER Paae 37 Lotus Service Notes Section MN BATTERY START ALTERNATOR amp IGNITION H gt BATTERY I 14 IGNITION START OROP OUT D FUSEBOX IGNITION UNFUSE gt G IGNITION FUSED 2 gt if S de BRIDGING LINK Ze OR COBRA dc IMMOBILISER S 3 B N t p T 3 y 2 4 ER lt Ja ug zz 59 oc 2 2 A MULTI FUNCTION C Qu 9 Big
78. 8 imp pt Oil ch nge interval 9 000 miles 15 000 km Transmission gearbox amp final drive Only specified lubricant Texaco MTF 94 A111F6017V Capacity refill 2 1 litre 3 7 dry 2 4 litre 4 2 imp pt Oil change interval Filled for life Rage 1998 703 Lotus Service Notes Section OG Brake amp Clutch System Type Specification Capacity brake clutch Fluid change interval Engine Coolant Additive Type Concentration System capacity Coolant change interval 1998 N3 Non mineral non petroleum hydraulic fluid DOT 4 1 5 litre 0 5 litre 12 months Unipart Super Plus Anti Freeze amp Summer Coolant 50 8 0 litre 24 months Pane 3 Lotus Service Notes Section OG MAINTENANCE SCHEDULE M111 ELISE LSL48B Date eene Owner s Name 2 2222 2222 eere Vehicle Registration No MAR EE Recorded Mileage Months Since Last Service Job NO aaesessesssreneaa 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 either within 1 000 miles 1 600 km of the distances stipulated or within one month of the anniversary of the previous service wh
79. 82 Nm 58 60 Ibf ft When slackening or tightening the track rod end locknuts it is important that the torque reaction is re sisted using the track rod end flats and that the ball joint itself is not allowed to be stressed 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 be coming 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 Camber angle Vertical Wheel centreline SEH 1998 02 Lotus Service Notes Section The early type uses a split Nylon bush secured to the chassis the lower wishbone front pivot bolt and spacer tube with a secondary 5 bolt clamping the two halves of the bush below the bar Washers welded to the anti roll bar bear against the outer sides of the bushes to locate the bar laterally The bush should be lubricated on assembly with MoS type grease Excessive radial clearance between the bar and bush may cause knocking noises which can be reduced by removing material from the joint face of the split bush to
80. At normal running temperature when the throttle is closed and engine speed is above about 2 000 rpm indicating engine overrun the fuel supply is shut off to enhance economy and reduce emissions Overspeed fuel cut off At a specified engine speed the injectors are cut off in order to protect the engine from overspeeding Oxygen sensor feedback By measuring the oxygen content of the exhaust gas any adjustment neces sary to maintain the air fuel ratio to that required by the catalytic converter for optimum conversion efficiency may be computed by the ECM An electrically heated oxygen sensor is used to ensure its speedy attainment of working temperature after a cold start Battery voltage correction The ECM senses battery voltage and applies a correction factor to take account of any variation in fuel delivery due to battery voltage fluctuation An idle air control valve mounted on the throttle body is used to regulate the amount of air by passing the throttle plate and hence control engine idle speed Two types of ignition system are used both controlled by the ECM Standard engines use a single ignition coil mounted on the right hand side of the cylinder block and a distributor driven from the rear end of the inlet camshaft VVC engines use a distributorless ignition system DIS which employs a pair of double ended ignition coils and a waste spark system whereby each coil fires two spark plugs simultaneously 1 2000 7 01 Page
81. BULK 15 INSTR PACK DIL 2000 03 LOrE gt FUSE A1 REAR FOG SHEET 15 SPLICE B G FUSE 83 7 5 amp SIDE LIGHT SWITCH N D IMMOBILISER 19 SHEET 8 INSTR FUSE 12 FAN ES COOLING FAN MAN n2 Page 29 E Lotus Service Notes Exige EXIGE ECM SENSORS POWER 4 as n 79 11 i NOTE RESISTOR IS APPROXIMATELY 50mm BACK FROM ECU CONNECTOR 67 BULK 17 BULK 10 sheet 4 2000 03 Rex Lotus Service Notes Exige EXIGE WIPER MOTOR 2000 03 iim RS Lotus Service Notes Exige EXIGE INDICATOR HAZARD LAMPS SAT LER b HAZARD FLASHER MODULE CONN CAV 4 w RH LIGHT CONN CAV 4 ener 2000 03 EG Lotus Service Notes Exige EXIGE RADIO AND CIGAR LIGHTER CIRCUIT LH REAR SPEAKER RH REAR SPEAKER sheet7 ___ 2000 03 RE Lotus Service Notes GE INSTRUMENT PACK CIRCUIT SPEEDOMETER SSES 2000 03 EO EXIGE IMMOBILISER BULK 41 2000 03 SS EG Lotus Service Notes Exige EXIGE HEADLAMP CIRCU idi 2000 03 SEE SHEET 11 COLUMN STALK SEG SHEET7 RADIO D SEE SHEET 8 INSTRU PACK RB gt SEE SHEET 13 CIGAR BULK 32 FHC SPLICEL J cavs RH HOL HC CAVB 4 PLICE CAV3 RH SIDE LIGHT CONN CAV 3 PLATE 1 RH HDL HC 1 CHMSL HC 4 L sheet 12 2000 03 TUM a iade 2000 03
82. Canister purge idle contro Ignition OBD2 connector Alarm system immobiliser Fuel pump Starter Solenoid Engine management Injectors ignition Supply a XIGE CIR DIAGRAM IN Circuit Sheet Starter Alternator ignition 1 Fuel Pump Ignition Coil 2 Radiator Fan ECM Control 3 ECM Power Supply Sensors 4 Wiper Motor 5 Turn Indicators Hazard Lamps 6 Radio amp Cigar Lighter 7 Instrument Pack 8 Meta Immobiliser 9 Meta Alarm 10 Headlamps 11 Sidelights 12 Horn 13 Rear Fog Reverse Brake Lamps 14 Interior Fan 15 GLOSSARY OF TERMS Abbreviation Expansion Location IMHC IMmobiliser Harness Connector Rear electrical box BULK BULKhead 48 way circular connector Rear electrical box FTHC Fuel Tank Harness Connector Rear electrical box FTU Fuel Tank Unit connector Top of tank left side AHC Alarm Harness Connector Behind battery OP CONN OPtion CONNector Rear electrical box FHC Front Harness Connector 1 amp 2 Front compartment right side CHMSL HC Central High Mounted Stop Lamp Harn Conn Engine bay left side FOG HC FOG lamp Harness Connector Rear clamshell HDL HC HeaDLamp Harness Connector Behind light pod RHC Rear Harness Connector Rear compartment left side 2000 03 IOME GNITION UN IGNITION FUSED FUSE A7 10 amp SPLICE SEES 3 IGNITION START DROP O CRANK RELAY rear bulkhead SPLICE sheet 1 2000 03 Page 27 28 EXIGE FUEL PUMP AND SEE SHE
83. Composite pane bolted to topshell Removeable for competition use Rear Shroud Composite panel protects silencer and supports rear diffuser Bolted via brackets to the rear subframe Rear Aerofoil Carbon fibre moulding bolted to alloy support plates Mudguards Separate close fitting carbon fibre mudguards are used on each wheel mounted to the hub carrier Side intake duct Sill panel Engine bay rear wall Page 4 Windscreen frame Z L LL Jy Electronics housing Access lid Cockpit tub Side closing panel Cockpit side screen 5538 Front splitter spoiler Front mudguard Rear aerofoil Rear mudguard a d Aerofoil support plate Rear shroud 2000 02 Lotus Service Notes 340R Removal of Topshell The body topshell is secured by threaded fasteners Removal of the topshell requires also that the seats be removed and the roll over bar fixings released to allow the bar to be tilted forwards 1 Remove the rear aerofoil from the mounting plates 2 Remove both seats from the car by releasing the seat runners from the floor and unthreading the harness straps 3 Release the spherical vacuum reservoir from the roll over bar left hand backstay and cut any tie wraps around the backstays Unplug the rear harness connector at the left hand lower corner of the engine bay 4 Release the over bar from the top of both ch
84. ECM start the engine if possible and run until it stops from starvation Crank the engine for a further 10 seconds the engine is a non runner pull out the fuel pump fuse and crank the engine for a total time of 60 seconds to minimise residual fuel pressure Disconnect the battery Use a shop towel to absorb the small amount of pressurised fuel remaining as the fuel feed pipe is disconnected at its push fit connector between the fuel filter and fuel rail inlet hose pull back the collar to release the grip of the connector on the pipe Plug the pipe ends In a similar manner disconnect the low pressure fuel return hose To remove the rear clamshell refer to Section BN From beneath the car Drain the coolant and transmission oil Remove the exhaust downpipe between the exhaust manifold and catalytic converter Remove the gear cables from the transmission lever spigots prise off and pull off the spring clips retaining the outer cables to the abutment bracket Release the earth braid from the transmission end case and the throttle cable from the sump P clip Release the engine steady arm from its anchor bracket on the rear of the the sump At each side of the car Release the two bolts securing the top ball joint plinth to the hub carrier taking note of the camber adjustment shim plates The inboard C V joint is retained in the transmission by a rounded section circlip and may be removed using a special wedge tool T0
85. Elise 111S Compared with the standard Elise transmission the final drive is lowered from 3 94 1 to 4 20 1 first and second gear ratios are raised and fifth is lowered Compared with the 111S the overall ratios are raised slightly due to the larger diameter wheels used on the Exige The only lubricant recommended for the Exige transmission is Texaco MTF 94 available under Lotus part number A111F6017V Gear Ratio Final Drive mph km h 1000 rpm First 2 92 1 5 8 9 3 Second 1 75 1 9 9 15 9 Third 1 31 1 4 20 1 13 1 21 1 Fourth 1 03 1 16 7 26 9 Fifth 0 85 1 20 2 32 5 Reverse 3 00 1 2000 03 17 Orr WH TYRES The Exige uses alloy road wheels made by Rimstock and featuring the 12 spoke black finish design used on the race series cars Wheel diameters at 16 and 17 inches front and rear are increased by one inch over standard Elise with rim widths of 7 and 8 5 inches Lotus engineers have worked with the tyre manufacturer Yokohama to produce an A039 tyre specifica tion for the Lotus Exige to optimise performance on both road and track When replacing tyres ensure that the correct Lotus specification of the tyre is fitted identified by LTS following the size designation on the tyre sidewall The 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 i
86. Expansion valve body e Lower clamp plate tapped O ring seal Evaporator outlet pipe i d Evaporator inlet pipe H 4 Before refitting renew all the connector O rings and coat with an approved refrigerant 5 Fitthe 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 88 kg of R134a 2000 04 SES 3 Lotus Service Notes Section 13 N The a c evaporator is mounted in a housing which includes the fresh air recirc flap flap actuator and a c thermostatic switch The unit sits on foam pads in the passenger side of the chassis climate chamber sealed to the fresh air and recirc ports with foam strip No direct fixings are used to secure the unit which is retained by the clamping action of the battery tray mounted above it To Remove Evaporator Unit 1 Remove the front clamshell 2 Remove the radiator duct outlet fence 3 Disconnect and remove the battery Remove the battery tray from the chassis 4 Recoverthe refrigerant Remove the a c pipe between expansion valve and receiver drier and between expansion valve and sill connector block 5 Disconnect the harness connector to the thermostatic switch and the vacuum pipe to the intake flap actuator 6 E
87. Fixing screws inside door shell Page 11 Y Lotus Service Notes Section BN BN 7 DOOR BEAM amp HINGE The door shell is bolted to a hollow section extruded aluminium alloy door beam hinged at the front end to the B post and carrying the door latch mechanism via a bracket at its rear end The front end of the door beam is welded to a second extrusion which together with a pair of steel bushes forms the rotor of the door hinge The hinge stator or hinge bracket is bolted to an outrigger on the chassis and houses two maintenance free plastic bearings inside of which the rotor bushes pivot 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 align ment 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 align ment to be adjusted in steps of 1mm 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 Shimplate TEn
88. Insert the Security System programme card into the scanner tool slot label uppermost vii Plug the security dongle into the scanner tool viii Press F2 Password Security System In order to control and monitor the security operations performed in the field using the Lotus Check a password system is used in conjunction with nominated supervisors at each dealership On receipt of the Lotus Check kit the accompanying Supervisor Password form should be completed and telefaxed to Omitech Instrumentation Note that the serial number etched on the back of the security programme card must be quoted Omitech will then telephone the supervisor with a password comprising a sequence of eight button presses on the six button scanner tool The password should be noted and kept secure by supervisor for only his her use This password allows 50 security operations to be performed where such an operation is defined as either ECM matching or transmitter key matching The supervisor allocates between 1 and 20 operations or charges to a user password of his her choice which is used by a technician when performing the actual task Page 8 E Lotus Service Notes Section MN The user password may be changed or recharged by the supervisor at any time Each time a security opera tion is performed a charge is debited against that supervisor password with the remaining number of charges advised via the scanner display When this number reduces to 22
89. 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 Fit the wiper motor assembly windscreen washer jets and demist vents Ensure that the cant rails are available and assembled with their catch plates and new front end foam seals Check that the cant rail striker plates are fitted to the roll over bar Prepare and re activate the old adhesive bead on the chassis using Betawipe 4000 see sub section BM 5 Clean and prime the bonding area on the new windscreen frame with Betaclean 3900 and Betaprime Page 14 E Lotus Service Notes Section BM 5404 see sub section BM 5 Apply a bead of Betaseal mate adhesive see sub section BM 5 to the windscreen frame flange and fit the frame panel into position 15 Locate the top of the windscreen frame by fitting the cant rails into position and secure the frame such that the cant rails are held against their striker plates on the roll over bar but with out the foam seals on their front end being compressed After further assembly the thickness of the header rail moulded carrier strip and tongue strip see sub section BN 14 provide the appropriate seal compression to locate the cant rails Windscreen frame bonding sills not shown Windscreen frame XN Baffle panel Bonding path
90. LHD 5 point driver s harness kit Alloy fuel tank Camber shim plates Engine Upgrade Delete air intake resonator valve Remove the air intake resonator valve and control mechanism including the vacuum reservoir and two solenoid valves Re plumb the MAP sensor Discard the secondary air cleaner at the airbox inlet and connect the intake trunking directly to the airbox with the primary air cleaner at the front end of the trunking which can be sited close to or connected to the air intake duct on the LH flank Take care when washing to avoid directing jet wash equipment into the intake duct blank off if necessary Delete breather rail Remove the steel breather rail from the inlet tracts Remove breather hose from cam cover to rail Fit alloy blanking plugs to inlet tract spigots Delete charcoal canister Remove the charcoal canister and plumbing Vent the fuel tank breather pipe from the roll over valve to atmosphere E CEST C UNE GM MN IO EET Ne ES Page 36 y Lotus Service Notes Section Delete IAC valve Remove the idle air control valve mounting bracket and plumbing Fit blanking plugs inlet tract spigots on manifold underside Fit blanking grommet to backplate Fit breather hose kit Remove the screenwash bottle and battery clamp bracket from the front chassis well Cut the top bottle mounting portion of the bracket from the lower battery clamp section and paint protect the
91. Lotus Service Notes Section PF PF 1 GENERAL DESCRIPTION The principal components of the heater ventilation system comprise a heater matrix unit incorporating an air blend flap a blower fan a diverter flap assembly and four fascia outlet vents The system provides heated or ambient air to the fascia vents or footwells via a simple 2 slider control on the fascia together with a four speed blower fan selector switch Airflow from each of the fascia outlet vents may be individually adjusted for volume and direction by direct manipulation of the vent and may be optimised for either wind screen demisting or face level ventilation Air for the ventilation system is taken from the radiator air intake duct via open ends in two of the crush tubes in the composite crash structure bonded to the front of the chassis A pair of holes in the chassis front crossmember mate with these tubes and admit air into the heater unit on either side of the heater matrix The heater matrix is a water air heat exchanger mounted vertically in a plastic mouiding housed in the space between the front ends of the chassis rails in the front services compartment and is fed with engine coolant at all times no water valve is used from the cylinder head outlet pipe Water returns to the engine via a water rail running around the back and left hand sides of the engine Water is carried from and to the engine bay by aluminium pipes clipped to the outboard sides of the chassi
92. Notes Section MN amp INTERIOR FAN BATTERY FUSEBOX IGNITION START DROP OUT gt IGNITION UNFUSE DI gt IGNITION FUSED D FAN SPEED SWITCH e NN Ne 2 RESISTOR BLOCK 5 AU 5 2 Sa z D i amp oO 19 gt 9 RADIO amp CIGAR LIGHTER FUSEBOX BATTERY IGNITION START DROP OUT D FUSEBOX IGNITION UNFUSED D IGNITION FUSED AER IAL Sjo 5 1 N N 412 SIDELAMPS SEE SHEET 9 o c CIGAR LIGHTER 22 V RB 2 SIDELANPS E SEE SHEET 9 RADIO T d 1 foil y 2 zc d ool a 5 m S i 1 t E c j _ 1 PEAS Ru REA PEAREA SFE AKER i E 4 23 D B A Se POWER 4 GROUND STRUCTURE MAXIFUSES IGNITION SWITCH FUSEBOX HEAL AMP CIRCUIT ENGINE NANAGE MENT CHASSIS c T oo FYEL PUMP REAR HARNESS CONNECTO mH R 8 SHEET 14 EO INTER HARNESS CONNECTORS CONNECTOR ON CONNECTOR ON MAIN HARNESS MATING HARNESS FRONT amp REAR HARNESS CONNECTORS FHC 4 RHC SLL D of o
93. OVERHAUL 11 MANUAL GEARBOX 5th Reverse Selector with reverse brake The 5Sth reverse selector 1 is secured to the selector shaft by a roll pin 2 The selector incorporates the components for the reverse brake operation This comprises of a lock plate 3 a retaining spring 4 The spring retains the lock plate in position with The two ends of the spring located under two Taptite screws 5 which are positioned either side of the 5th reverse selector 37M1292 Interlock Assembly 37M1165 NOTE modified interlock assembly having 2 springs has been introduced this assembly may be fitted as a replacement to early gearboxes 1 Withdraw shift shaft from gearshift holder and arm guide 2 Release lug on arm guide from slot in interlock 3 Slide gearshift holder off arm guide Differential Assembly QA 1 Remove bearings using tools 18G 2 18G 2 3 and 18G 1397 discard bearings 12 OVERHAUL REVISED 12 97 MANUAL GEARBOX 0 0 Differential Assembly 1 Check gear teeth for wear chipping and signs of overheating CAUTION It is not possible to overhaul Torsen differentials Replace complete assembly if any of the above are apparent Torsen differential 2 Check speedometer drive gear for damage replace if necessary 37M0182 3 Remove speedometer drive gear using a suitable three legged puller and thrust button Standard differenti
94. Remove and discard cylinder head gasket OVERHAUL 3 ENGINE Cylinder head K16 VVC engines remove CAUTION If crankshaft is to be removed during overhaul it will be necessary to check and record crankshaft end float prior to removing cylinder head 1 Remove and discard camshaft timing belt CAUTION Do not rotate crankshaft whilst timing beit is removed and cylinder head is fitted pistons will contact the valves 18G 1570 12M1770 33 Assemble cylinder liner retainer clamps 18G 1736 to cylinder head bolts Position retainer clamps on cylinder liners ensuring clamps do not protrude over liner bores Screw cylinder head bolts into oil rail and tighten sufficiently to retain clamps CAUTION Ensure that bolts used are those originally fitted in that location M124932A 2 Ensure that tool 18G 1570 is fitted to camshaft gears v 3 Suitably identify each camshaft gear to its respective camshaft and using tool 12 182 to restrain camshaft gears against rotation remove bolt and plain washer securing each camshaft gear 4 Remove tool 18G 1570 remove camshaft gears 32 OVERHAUL ENGINE Remove screws securing timing belt upper rear Later engines cover to cylinder head and rear of cover to coolant pump remove cover NOTE This ts the longest of the rear cover N securing screws M124939 oe pe 12 Remove bolt securing camshaft sensor remove sensor 13 Remove and
95. SS ee i fnac jr z I E X i 1 Ed wel UE i 2 n 2 gt 1 i in 1 i 1 A E S ds e i Laun up BO Oi pou Dg i we lt NE 1 Ve Te vm 1 u i 1 D i EN gt J a toe PHC 7 IT gt ES E SE SHEET 6 Section DIRECTION INDICATORS amp HAZARD LAMPS FUSEBOX BATTERY gt IGNITION ISTART DROP OUT D FUSEBOX IGNITION IUNFUSEDI D IGNITION FUSED gt HAZARD SWITCH 12 5106 AMPS SEE SHEET 9 E i HAZARD FLASHER LCK al i o 7 ou ESTA 1 i 4 i 3 m ely a 1 91 aL 1 10 ALARN ALARM i SEE 5 BEE SHEET 45 Aer SEE SHEET 345 d Gi MEER MAIN BEAM WARNING i EI x 5 5 i b LH LAMPS 75 0 i E SHEET 7 DIP BEAM Ar B BATTERY gt IGNITION ISTART DROP OUT gt IGNITION UNFUSED S gt Sp IGNITION FUSED gt i gt TO SIDELAMP SWITCH 7 SEE SHEET 9 lt N wm 2 HEADLAMP SWITCH ES 3 2 ak D gt 1 14 5 je L EL TTE 2 _ U TO SIDELAMP SWITCH SEE SHEET 9 gt TO FOG
96. SUSP Geometry check ride height 2 persons tank fuel front rear Alignment Camber For Motorsport suspension settings see Section XA ELECTRICAL Light Bulbs Headlamps Driving lamps Front side parking lamps Side repeater lamps Front amp rear turn indicators Stop tail lamps High mounted stop lamp Rear fog lamp Reversing lamp Licence plate lamps interior lamp Fascia switches System voltage polarity Alternator Battery type Cranking power reserve capacity European Type Number ETN TRANSMISSION Independent Upper and lower wishbone co axial coil spring telescopic damper 140 mm below front end of chassis siderail 140 mm below rear end of chassis siderail 1 2 mm toe in each side 0 2 0 0 18 toe in each side 0 03 0 Max difference side side 0 2 mm 0 03 1 8 0 2 Max side side 0 2 Wattage Type 60 55 H4 P43t 55 H1 5 W2x4 6d 5 W2x4 6d 21 SCC BA15s 5 21 SBC BAY15d 11 891 21 SCC BA15s 21 SCC BA15s 5 SU 8 5 8 10 SU 8 5 8 1 2 W2x4 6d 12V negative earth 85A Tungstone 063 380 A SAE 210A DIN 38 Ahr 60 minutes 543 16 5 speed manual transaxle Type Bevel gear differential Standard Gear Ratio Final Drive mph km h 1000 rpm First 3 17 1 5 5 8 9 Second 1 84 1 9 5 15 3 Third 1 31 1 3 94 1 13 4 21 5 Fourth 1 03 1 16 9 27 2 Fifth 0 77 1 22 9 36 8 Reverse 3 00 1 1115 close ratio G
97. The 1 4 kW starter motor was introduced at the following change point approx VIN V 685 February 97 Note that a label on the motor body identifies the type Fuse Location LH side of rear luggage compartment Early cars 1 0 kW motor engine management 40A Maxi fuse On later cars the fuse holder is still fitted but without a fuse d i ECM Fuel pump fuse Front services compartment RHD shown Wiper motor cover Later cars 1 4 kW motor engine management 40A Maxi fuse On LHD cars the other fuses shown are sited on the RH side of the compartment but the engine manage ment fuse remains on the LH side Page 28 Lotus Service Notes Section MN 11 CIRCUIT DIAGRAMS Prior to Oct 97 Circuit Start Alternator amp Ignition Fuel Pump amp Cooling Fan Engine Management System Alarm amp Immobiliser Lucas Interior Lamp amp Horn Alarm amp Immobiliser Cobra Interior Lamp Stop amp Reverse Lamps Direction Indicators amp Hazard Lamps Headlamps Sidelamps amp Fog Lamps Instruments Windscreen Wipers Interior Fan Radio amp Cigar Lighter Power amp Ground Structure Inter Harness Connectors Fuses Sheet 10 11 12 13 14 15 16 Page 29 E Lotus Service Notes Section MN Page 30 Lotus Service Notes Section MN START ALTERNATOR amp IGNITION gt
98. Tighten bolts in sequence shown to 5 Nm then in same sequence to 30 Nm CAUTION With bearing ladder fitted crankshaft will be tight do not rotate crankshaft more than absolutely necessary until cylinder head bolts are tightened to the correct torque 8 Fit cylinder liners and pistons CAUTION Ensure that cylinder liner retainer clamps 18G 1736 and nylon nuts are fitted immediately cylinder liners are inserted into cylinder block 9 Lubricate crankshaft big end joumals and bearing shells with engine oil Carefully pul each connecting rod into place fit big end caps noting that featherways abut fit and finger tighten dowel bolts in their original fitted order 10 Tighten big end dowel bolts in pairs to 20 Nm 45 NOTE Until the cylinder head is fitted crankshaft will prove difficult to rotate once big end bolts are tightened 11 Using feeler gauges check that end float of each big end bearing connecting rod is between 0 10 to 0 25 mm 12M1781 12 Apply continuous beads of sealant Part Number GUG 705963GM to paths on oil rail as shown then spread to an even film using a roller CAUTION To avoid contamination assembly should be completed immediately after application of sealant 13 Using assistance position cylinder block on its side and temporarily remove cylinder liner retainer clamps 18G 1736 CAUTION Take care not to disturb cylinder liners with retainer clamps removed 14 Fit oil
99. To replace the sensor unplug the electrical connector brown and unscrew from the hydraulic control unit Fit a new seal onto the sensor before inserting and tightening to 15 Nm temperature sensor ix 2000 01 Lotus Service Notes Section EMN 16 FUEL SYSTEM The fuel system is a high pressure recirculating type using tank submerged 3 stage impeller pump an in line canister filter a common fuel rail supplying all four injectors and a fuel pressure regulating valve controlling the return line to the tank WARNING The fuel line between pump and injector rail and the injector rail itself contain pressurised fuel both when the engine is running and after switching off This feature aids engine starting by reducing the time needed to build up operating fuel pressure and inhibiting the formation of vapour pockets in the supply line of a stopped hot engine i minimise the risk of fire and personal injury relieve the fuel system pressure before servicing the fuel rail or any related component See Fuel Pressure Relief Procedure below ii 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 r This procedure should be used prior to disconnecting any
100. a door is left open the alarm will repeat after a short delay and continue in this sequence for a total of ten cycles To Disarm the Alarm Press once the embossed red button on the transmitter key This command will be acknowledged by single flash of the hazard lamps accompanied short and a long buzz the alarm tell tale changing from steady to flashing illumination Note that the flashing of the tell tale prior to next switching on the ignition provides an indication as to whether or not the alarm had been triggered during the last armed period If the flashing is regular at one per second no triggering had occured and after 30 seconds the passive immobilisation will take effect and the tell tale light steady see above If the flashing is irregular a single flash followed by a 2 second break indicates that a door bonnet or engine lid sensor had been triggered during the last armed period 3 flashes followed by a 2 second break indicates that the microwave sensor interior movement sensor had been triggered during the last armed period Note that if the alarm is triggered and is disarmed when the siren is sounding the first press of the red button will silence the siren but leave the system armed Press a second time to disarm Switching Off Interior Movement Sensing H an animal is to be left in the vehicle the alarm can be armed without the microwave sensor operating First arm the system in the usual way by pr
101. 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 QF 2 ADJUSTMENT 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 The master cylinder pushrod length requires adjusting only on assembly in order to ensure a the master cylinder piston is allowed fully to return under the action of its internal spring and open the port to the fluid reservoir b maximum effective stroke of the cylinder is achieved The effective length of the pushrod can be adjusted by screwing the hexagonal pushrod into or out of the pedal trunnion Too much preload will not allow the reservoir port to open whereas too much free play will not allow sufficient fluid displacement and may induce a rattle from the pedal To check the pushrod adjustment i Remove the locking grub screw 3 mm key in the side of the pedal trunnion and apply Permabond A131 to the thread Refit loosely ii Screw the pushr
102. a short delay and continue in this sequence for a total of ten cycles To silence the siren when the alarm has been triggered press once the larger of the two buttons on the transmitter key The siren will reset and the system will remain armed Disarming the Alarm To disarm the alarm prior to entering the vehicle press once the larger of the two buttons on the transmit ter key This command will be acknowledged by One flash of the hazard warning lamps Extinguishing of the alarm tell tale in the instrument panel If the tell tale is flashing intermittently the alarm has been triggered during the armed period see Trouble Shooting 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 running circuits either four minutes after switching off the ignition or one minute after switching off and opening and closing a door Immobilisation will be indicated by the alarm tell tale flashing and if initiated by the door being opened and closed two flashes of the hazard warning lamps Note that these indications are the same as those for the arming of the alarm but in this instance it is only engine immobilisation which is activated To start the car after immobilisation has been activated it is necessary to switch OFF the ignition and press once the large button on the transmitter key The al
103. above ii Connect fuel pressure test gauge T000T1386 into the supply line between the fuel filter and fuel rail using adaptor TO00T1387 Test gauge T000T1386 Adaptor T000T1387 Fuel filter Fuel feed hose iti Disconnect the vacuum hose between the pressure regulator and the intake plenum iv With the engine idling the pressure gauge should read 2 9 3 1 bar If below specification progressively restrict the fuel return line between regulator valve and tank If the specification can then be achieved the regulator valve is faulty If this makes little or no difference the fuel pump may be restricted or faulty If above specification the regulator valve may be faulty v With the engine still idling re connect the vacuum hose to the regulator valve The pressure should drop to approximately 2 2 bar If the pressure does not drop check the hose for kinking or blockage or replace the regulator valve vi Switch off the ignition and observe the pressure drop after one minute Pressure should not drop by more than 0 7 bar Too great a pressure drop may be caused by a faulty regulator valve b faulty non return valve in the fuel pump c leaking injector If clamping off the return hose reduces the pressure drop a faulty regulator valve is indicated If clamping off the supply hose reduces the pressure drop a faulty fuel pump is indicated If clamping off both hoses does not reduce the pressure drop a leaking
104. air outlet grilles are bonded to the underside of the panel with Betamate adhe sive and a plastic finisher strip used to tidy the joint Latch Mechanism single latch is mounted at the centre of the rear edge of the bonnet and consists of a striker pin Page 4 e Lotus Service Notes Lotus Service Notes Section BN clamped to the bonnet reinforcing rib with a tapping plate and locknut and a latch slider plate mounted on an extension to the wiper motor bracket itself fixed to the scuttle A bowden cable connects to the slider plate by a clamp screw and terminates in a vertically mounted release handle in the top of the driver s footwell In the event of cable breakage access to the latch is available after removing the driver s side front wheelarch liner Adjustments The height of the rear edge of the bonnet is controlled by the setting of the striker pin which may be screwed up or down as required and by a rubber buffer at each rear corner of the panel aperture The buffers are mounted on the heads of fixing bolts which secure the front topshell to the windscreen buttresses The height of the front edge is controlled by the number of shim plates fitted between the hinge and the bonnet and the slotted holes in the hinge arm allow for positional adjustment of the panel If removing the bonnet take note of the shim stack for re assembly and when the bonnet is removed guard against damage being caused to the r
105. and minimises the time spent adjusting to changed operating conditions A summary of the sensors supplying inputs to the ECM and the components to which the ECM supplies output control follows Crankshaft position Ignition coil Manifold absolute pressure Fuel injectors Engine coolant temperature Idle air contro valve Intake air temperature Fuel pump relay Exhaust oxygen content ECM Diagnostic connector Throttle position Oxygen sensor heater relay Camshaft position VVC VVC control solenoids Oil temperature VVC Main relay Diagnostic input Radiator cooling fans Battery supply Starter signal Earth supply Vehicle security signal Note that the ECM on bootbox cars built between September 98 and February 00 was originally mounted on the front side of the composite bootbox In order to improve electromagnetic shielding a steel mounting plate was introduced to secure and earth the ECM directly to the rear subframe All such cars should be retro fitted with this steel mounting bracket If a replacement engine ECM is fitted or security 5AS module the Lotus Check tool must be used to match the engine management and security modules VVC models may use the MEMS 2J card for this operation see EMN 2 whereas standard cars must use the security 5AS card and the password system see section MN 2 MANA 04 Page 7 E Lotus Service Notes Section EMN Before removing an ECM first disconnect the battery earth lead be
106. any free play in a joint but care must be taken not to confuse this with transmission backlash which may be considerable Any symptoms that could be due to worn driveshaft joint assemblies should be investigated and rectified without delay since safety consid erations are always of paramount importance Page 6 Lotus Service Notes Section FH 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 and is retained by a round section spring circlip on its end Each of the two transmission output oil seals runs on a stepped shoulder on the C V joint spigot shaft The outboard end of each driveshaft carries a second C V joint whose spigot shaft is used to clamp the hub and wheel bearing into the hub carrier via a thread on the end of the shaft Outboard 6 ball Birfield joint Inboard plunging tripod joint Driveshaft SS Hub splines Circlip groove C V joint gaiters 111 Revised Transmission Output Seals A type seal In order to reduce the possibility of seal damage during driveshaft insertion the two transmission output shaft seals were modified in July 96 and fitted from transmission number C6BP 2009713 The new B type seals incorporate a steel insert to protect the seal lips and have a location flange on their outside diameter When replacing a seal compatibility with the driveshaft
107. application answer Proceed After the test has been run a print out should be obtained as the results are not displayed in any other manner If any default flags are shown the Pre Test should be run again to establish whether the fault is still current If not current i e the fault is intermittent and is no longer detected the memory will be cleared of the default flag and the next time the test is run no flag will be shown Be aware that if a successful repair is made the next time a Pre Test is run the fault will still be flagged as having been detected since the previous 2000 ft Lotus Service Notes Section EMN E test Run a further test to verify the repair The programme menu is available only on the MEMS 2 card and allows matching of the engine management and security DAG modules if one or the other is replaced At the instant of ignition is switch on the security 5AS module sends a unique coded signal to the engine management ECM which must be recog nised by the ECM before it will allow the engine to run If no code or an incorrect code is received the ECM will prevent fuelling of the engine although the engine may crank typically resulting in engine start followed immediately by a stall if either the engine ECM or security 5AS module is replaced or swopped from another vehicle the ECM must be taught to recognise the coded 5AS signal by selecting MEMS MATCHING from the PROG menu and following th
108. assembly in the reverse order to disassembly tightening the inlet pipe to rail screws to 4 Nm 17 IGNITION SYSTEM The ignition system comprises a single ignition coil mounted on the RH side of the cylinder block a distributor driven from the rear end of the inlet camshaft and low tension control circuitry within the ECM The ECM controls ignition timing based on inputs from the following sensors Crankshaft position sensor supplies engine speed and crankshaft position information Manifold absolute pressure sensor supplies engine load information Engine coolant temperature sensor allows timing variations for optimum cold driveability and idle The main control over engine idle speed is attained by the use of the idle air control valve However for rapid response and to inhibit stalling when additional loads are placed on or removed from the engine the ECM varies the ignition timing to achieve idle stabilisation An observation of idle ignition timing will see a constantly changing reading The ignition coil has a low primary winding resistance 0 63 to 0 77 ohms at 20 C in order to allow full high tension output to be reached faster than normal and make coil operation more consistent throughout the engine speed range Ignition coil Page 24 2000 0 1 IO Lotus Service Notes Section EMN A rotor arm is mounted on a D shaped extension to the rear end of the inlet camshaft and is retained by a patchlock screw Al
109. between regulator valve and plenum 4 Release the fuel return hose from the right hand end of the fuel rail and plug the connections 5 Remove the two screws securing the fuel inlet pipe to the left hand end of the rail and withdraw Discard the O ring and plug the connections 6 Unplug the injector harness connector and release from its retaining bracket 7 Remove the two bolts securing the fuel rail to the inlet manifold and carefully withdraw the rail complete with the four injectors and pressure regulator valve Take great care not to damage the injector tips during the removal process Cap the injectors and plug the manifold ports to prevent dirt ingress Pressure sensing hose Fuel pressure regulator valve Fuel inlet pipe Injector retaining clip Fuel return pipe Fuel injector Inlet manifold 2000 01 NM Lotus Service Notes Section EMN 8 To remove an injector from the rail unplug the harness connector remove the clip and withdraw the injector from the rail Discard the two rings 9 Before re fitting the injectors and rail clean the injector recesses in the rail and inlet manifold and fit each injector with 2 new O rings lubricated with silicone grease Fit the injectors into the rail and retain with the spring clip 10 Carefully insert each of the injectors into its inlet manifold bore and retain the rail with the two fixing bolts tightened to 9 Nm 11 Continue re
110. by too low a pressure third switching point at 17 5 bar is used on Exige models for condenser fan control input to the engine ECM see sub section PH 4 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 Expansion Valve The expansion valve block is fitted into the high and low pressure lines at the evaporator and provides 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 The expansion valve senses the pressure of refrigerant leaving the evaporator and modu lates the valve inlet opening in order to provide optimum cooling performance 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 around the heater matrix through the blower fan and 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 over the evaporator surface This airstream is consequently cooled and is directed through the various out
111. 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 Break out Column slotted insert Column lower fixing Normal Condition Chassis scuttle beam 5 Column flange broken out of insert Collapsed Condition Dimensional Check If the vehicle is involved in an accident or any part of the column is subjected to an abnormal load 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 S
112. components must be adjusted in a specific sequence to ensure full and correct throttle operation without cable strain The procedure is detailed in sub section JH 8 but may be summarised as follows Adjust the pedal upstop for a pedal height 30mm below brake and clutch pedals Adjust the ball jointed pull rod connecting to the pedal to achieve a gap of 20mm between outer cable abutment and multiplier lever pivotting link Adjust the locknuts at the engine end of the outer cable to allow a small amount of free play to accommo date temperature change effects Adjust the pedal downstop so that fuil travel of the throttle butterfly can just be achieved without allowing the cable to be strained 4 RONI R The ECM is an electronic processor mounted a panel either at the left hand side of the rear luggage compartment pre bootbox or at the rear of the engine compartment with bootbox The immobilisation feature of the vehicle security system results in the ECMs for engine management and security being match coded such that the engine module must recognise a coded signal from the security module before the unit becomes operative i The engine ECM is an adaptive unit which learns the optimum setting of the idle air control valve and the fuelling offset required to achieve the correct exhaust oxygen content for a particular engine relative to its wear and performance characteristics This feature speeds the response of the system
113. cut surface Rivet the bottle mounting bracket to the LH side of the engine bulkhead and fit the washer bottle with motor aperture blanking grommet to the bracket to act as oil catch tank Remove the breather hose between cam cover and airbox and fit the grommet to the airbox hole Use the breather hose kit to connect the two cam cover breather spigots to the catch tank cutting a 13 mm hole in the top surface of the bottle to admit the breather hose and a similar hole in the bottle filler cap to allow breathing Fit race exhaust system Remove the catalytic converter and standard muffler and replace with the track muffler Fit lower temp thermostat Replace the standard 88 C thermostat with the 82 C thermostat Exchange ECM Replace the standard ECM with the reprogrammed unit and return old unit to Lotus RHD only Fit oil cooler kit See separate instruction sheet LSL388 101 MOP Inlet Cam Pulley The standard engine inlet cam timing is 105 ATDC maximum opening point The modified pulley supplied in the kit allows the inlet cam timing to be advanced by 4 to 101 MOP 1 Remove the timing belt top cover 2 the engine to align the timing mark on the crankshaft front pulley with the safe position 45 mark 12 O clock on the timing belt lower cover Check that the camshaft pulley timing marks are aligned towards each other if not turn a further 360 3 Slacken the belt tensioner clamp bolt and remove tensi
114. earth point sensor Main harness at panel Engine harness connectors Engine management ECM s T harness connector aa dp DLC Relay module Inertia switch Page 25 E Lotus Service Notes Section MN Rear clamshell harness Connector to main harness High mounted stop lamp Licence plate lamp Front clamshell harness Connector to main harness mig Page 26 Eb Lotus Service Notes Section MN Centre tunnel harness routin Cigarette lighter terminals Rubber edging Foam pad Protective channel P N Into fuel tank bay Note use of P clips tie wraps and edge protection as shown Page 27 Lotus Service Notes Section MN MN 10 INTRODUCTION OF UPRATED STARTER MOTOR In February 97 the starter motor was uprated from 1 0 kW to 1 4 kW with attendent benefits to hot start performance In order to optimise the vehicle wiring harness in respect to voltage drop characteristics the power supply to the engine management system was revised and the main engine management Maxi fuse relocated from the rear luggage compartment to the front services compartment Updating an earlier wiring harness is not practical and starter motor replacement should be carried out on a like for like basis Fitting a 1 4 KW motor on an earlier car may result in sufficient voltage drop to the engine management system to prevent starting Change Point
115. embossed red transmitter button with the ignition key in any position the alarm tell tale will switch from steady to flashing illumination and the engine may be started If however the ignition is not switched on within 60 seconds passive immobilisation will again be activated To Arm the Alarm Remove the ignition key close the front bonnet and engine lid and close and lock both doors The roof may be either raised or stowed Press once the embossed red transmitter button This command will be acknowledged by two flashes of the hazard lamps accompanied by two short buzzes the alarm tell tale on steady The engine will be immobilised immediately on the arming command but other alarm functions require an arming period of about 30 seconds before becoming fully active If the alarm is armed whilst a door bonnet or engine lid is open or ajar the warning buzzer will sound continuously before after a period of 40 seconds the siren is sounded When the alarm is fully armed triggering will occur if a door bonnet or engine lid is opened movement within the passenger compartment is detected When triggered the self powered electronic siren will sound and the hazard warning lamps flash After 30 _ seconds these functions will switch off and automatically reset ready for any further triggering input If the ETSE Ea I NT EE EE TF BETES AEE OEE IT E Page 3 Section MN triggering signal is still present e g if
116. engines have their step heights graded on production The step heights V or Z together with the liner part number and colour code are marked on the outside diameter of the liner If cylinder liner s are to be replaced the replacement liner s must have the same step height as the original liner s Both step heights are available in red and blue grades of liner OVERHAUL 95 ENGINE Cylinder liners remove 1 Remove pistons 2 Remove cylinder liner clamps 18G 1736 3 Using assistance position cylinder block on its side CAUTION If original cylinder liners are to be refitted use a feit tipped pen to make suitable alignment marks between liner and cylinder block Do not etch or stamp liners 4 Using hand pressure push cylinder liners out towards cylinder head face of cylinder block remove liners CAUTION Keep cylinder liners in their fitted order Cylinder liners refit NOTE To enable cylinder liner retainer SCH clamps to be fitted when liners are inserted in cylinder block crankshaft and bearing ladder must be fitted 1 Fit crankshaft and bearing ladder 2 Using assistance support cylinder block on 2 wooden blocks 3 Remove sealant from cylinder block and if original cylinder liners are to be refitted from shoulder of liners 4 Clean cylinder liners and wipe dry CAUTION Ensure that if original cylinder liners are to be refitted reference marks made during dismantling are not e
117. fit bolts and tighten in sequence shown to 10 Nm 74 OVERHAUL All camshaft covers 5 Non VVC engines Fit air cleaner support bracket tighten bolts to 10 Nm 6 Locate HT leads in clips and press plug tubes on to spark plugs 7 Fit spark plug cover to camshaft cover tighten screws to 10 Nm 8 Position timing belt upper rear cover to cylinder head fit screws and tighten to 9 Nm NOTE Longest screw secures cover to ZN coolant pump 12 182 A NOTE Non VVC timing gears illustrated 9 Fit camshaft gears to their respective camshafts ensuring that on non VVC engines drive gear pins are located in correct slot in drive gears hold gears using tool 12 182 and tighten bolts to M8 bolts 35 Nm M10 bolts 65 Nm Camshaft cover and timing gears K16 engines fitted with plug top coil ignition system refit 18G 1570 M12 4946A NOTE VVC camshaft timing marks are A shown in the inset on the illustration 10 Non VVC engines Using tool 12 182 align camshaft gear timing marks 11 VVC engines Check that camshaft gear timing marks are still aligned reposition gears if necessary using tool 12 182 12 Fit camshaft gear locking tool 18G 1570 Later VVC engines 13 Lubricate a new O ring with engine oil and fit to camshaft sensor 14 Fit camshaft sensor fit bolt and tighten to 5 Nm 15 VVC and K16 engines fitted with manual timing tensioner Fit camshaft timing belt tensioner
118. 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 DRAIN REFILL PROCEDURE To drain the engine cooling system remove the header tank cap and disconnect the radiator feed and return hoses from the rear ends of the water rails running down each sill If necessary raise the front of the car to aid draining 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 Disconnect LH return hose at this point Page 4 3 E PS Lotus Service Notes Section KF Disconnect RH hose at this point To refill the system Refit the hoses and fill with the recommended coolant mix via the header tank Remove the bleed screw in the return water rail at the left hand side of the engine taking care not to misplace the sealing washer Water rail bleed plug Using radiator pressure test equipment pressurise the header tank to circulate the coolant When neces sary refill the header tank and repeat When a steady stream of coolant flows from the bleed port replace the screw and washer and tighten amp lt gt Pressure test pump Header tank Page 5 Lotus Service Notes Section KF 4 Release the front end of the LH front wheelarch liner to provide access to t
119. from the new switchbox Insert the terminated green wire from the new switchbox into the vacated fusebox cavity 7B Replace fuse 7 10A and refit the fusebox Operating switch Switchbox Green to new fuseholder Unterminated black to alternator dump resistor Prior to revised harness Black to battery negative Black to cavity B in 2 way master switch connector Unterminated green spliced to main harness white Green to new fuseholder With revised Unterminated black to alternater dump harness resistor Black to battery negative Unterminated green spliced to green cable extracted from fusebox cavity 7B Black to cavity B 2 way master switch relay connector Page 28 Section Lotus Service Notes 6 Use splice crimp solder and heatshrink to connect the new red 2 0 mm wire to the alternator dump resistor and connect the other end to the master switch relay terminal with the other re terminated battery positive cables 7 splice crimp solder and heatshrink to connect the unterminated black wire from the operating switch to the remaining wire on the alternator dump resistor Locate the resistor in its P clip by the side of the master switch relay 8 At the master switch relay small two way connector use the new red 0 75 mm wire to connect cavity A to the master switch terminal with the battery positive link A111M0109F attached 9 Inser the terminated black cable
120. from the operating switch into cavity B of the two way connector on the master switch relay 10 Connect the ring terminated black cable from the operating switch to the battery negative terminal 11 Reconnect battery 12 If the car is to be used in competition and the passive immobilisation system is required to be disabled extract the two purple and white cables from the Lucas 5AS module harness connector and tape back NOTE When the ignition is turned off ensure also that the operating switch is turned off as otherwise a battery drain will occur via the energised master switch relay Circuit diagram Prior to revised harness amp MAXIFUSES R gt STARTER MOTOR 17 W R 20 2 0 B 2 ALTERNATUR 4 DUMP RESISTOR SIEMENS RELAY VEHICLE BATTERY O B ULT BOWDEN MANULE PULL CABLE MASTER SWITCH 0 75 OPERATION WITCH ON OFF POSITION NEW FUSE SPLICE D Oe 10 29 E Lotus Service Notes Section Circuit diagram With revised harness BOX amp MAXIFUSES STARTER MOTOR SIEMENS RELAY VEHICLE BATTERY 12 W R 209 2 0 B 2 ALTERNATOR 4 DUMP RESISTOR 0 7551 R MASTER SWITCH BOWDEN MANULE PULL CABLE 0 75 OPERATION SWITCH ON OFF POSITION IGNITION gp SERVICES FUSE A7 IGN SWITCH lt w NO 10
121. front wheel alignment as detailed in sub section CG 2 HE 7 ADJUSTMENT OF RACK BAR THRUST PAD 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 theaded 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 12 to 16 Ibf 50 70 N 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 2 turn Rack housing O ring Threaded plug Wi Locknut Belleville washers Thrust pad Page 10 E Lotus Service Notes Section JH BRAKE SYSTEM amp PEDAL BOX SECTION JH M111 Sub Section Page General Description JH 1 3 Brake Fluid Check amp Change JH 2 3 Front Brake Pad Replacement JH 3 4 Rear Brake Pad Replacement JH 4 5 Parking Brake Mechanism JH 5 6 Brake Discs JH 6 9 Master Cylinder JH 7 10 Pedal Box JH 8 13 Caliper Overhaul JH 9 15 Page 1 Section JH E Lotus Service Notes LNOAVT 1VHANAD osip exyelq 14014 amp 4 E 2 2 NX ejqeo ayesg Bupyied sana
122. gauge sender assembly is mounted submerged in the left hand side of the fuel tank and utilises an electric motor to power a three stage impeller type pump and a reservoir canister to avoid fuel starvation from surge effects caused by vehicle acceleration and cornering forces The complete unit is spring loaded against the bottom of the tank by three telescopic legs carried on the end plate which is clamped by a mounting ring and O ring to an aperture in the top surface of the tank The pump is housed within a reservoir canister kept filled with fuel even at very low tank levels The pump connects with a port on the bottom of the canister fitted with a strainer sock in order to screen dirt particles from the fuel line and help separate any water content from the fuel The first stage impeller pump draws fuel from the tank via this sock and outputs it into the canister which fills up to its overflow port in the top surface The second stage impeller pump draws fuel from within the canister via another strainer sock and supplies the high pressure third stage tubine pump which outputs fuel from the top end of the pump into the flexible pipe con nected to the supply connection on the pump assembly top plate From here fuel is piped to the fuel rail on the Page 8 Lotus Service Notes Section LH engine from which it returns to the inlet connection on the top plate and spills into the canister to supplement the primary pump output and keep the ca
123. height for geometry check front 100 mm below front end of chassis siderail rear 110 mm below rear end of chassis siderail Road use Yokohama A038 R or Pirelli P Zero tyres Camber 2 0 0 2 0 max side side 0 2 Alignment 1 5 mm toe in each side 0 2 mm 0 max side side 0 2 mm Dry track use Yokohama A038 R tyres Camber 2 7 0 2 max side side 0 2 Alignment 2 5 mm toe in each side 0 2 mm 0 max side side 0 2 mm 340R E ENGINE The engine is based on the Rover 1 8 litre K series unit and is reworked a similar way to the VHPD 190 race version but tuned for road use Output of the engine is as follows Max power 132 5 kW 177 7 bhp 7 800 rpm Max torque 172 Nm 127 Ibf ft 6750 rpm Performance measures include a big valve cylinder head re profiled inlet and exhaust camshafts a new cast alloy 4 branch intake manifold with individual throttles large intake airbox and performance air filters large diameter 4 2 1 exhaust manifold and new muffler lightweight flywheel Lotus engine management system with maxiumum engine speed limited to 7 800 rpm Engine durability modifications include a forged crankshaft new forged connecting rods forged pistons with revised rings mechanical tappets Page 9 ege SOEN 340R Lotus Service Notes piouejos Huibseyo soyeuosey Joyeuosay eaul Josues anssaid 21 J
124. ici 1998 15 Lotus Service Notes Section JH 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 Operating Lever return spring Driving Return Stop Balls disc spring bolt inramps For the auto adjustment system to function correctly it is essential that each caliper 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 caliper levers are fully returned with the parking brake off measure the distance between the cable abutment and caliper lever as shown Caliper park brake lever Cable abutment Page 7 Lotus Service Notes Section JH 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 If fitted the diffuser undertray must be removed for access After adjustment re check the caliper lever off dimension LH lower wishbone 2 front pivot brac
125. in cold weather and or frequent or prolonged idling Air cleaner element Air Cleaner Element Air cleaner cover The air filter should be inspected at in tervals 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 Mainte nance Schedule but where a dusty or smog laden atmosphere prevails more frequent re placement 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 side of the engine bay Air cleaner housing Page 3 Lotus Service Notes Section To replace the filter element leave the hose attached and release the four over centre clips securing the top cover of the air filter housing Raise the cover and ensure that the filter element remains in the lower housing before swinging the cover aside Lift out the element and clean the inside of the filter housing and cover including the joint line recess Fit the new element into position in the lower housing and refit the top cover ensuring that the filter seal is correctly located in the cover recess Engage each of the four over centre fasteners and snap each clip closed Alternator Belt single multi rib type belt is used to transmit drive from the crankshaft to the alternator The belt requires no periodic maintenance other than a visual check of its cond
126. in the carrier channel and leave to cure overnight before re assembling Note that some penetrant lubricants e g WD40 have a detrimental effect on the bonding medium and should be used only with discretion To replace door winder mechanism 1 Remove the door trim panel Unclip the cap from the window winder handle release the retaining screw and withdraw the handle Release the seven fixing screws and remove the door trim panel 2 Remove the interior release control rod for improved access Unclip the contro rod from the interior release handie and unhook from the latch mechanism 3 Tapethe door glass in the fully raised position then remove the three fixings securing the lift mechanism to the door shell two fixings adjacent to the winder spindle one fixing through the static pivot of the primary scissor arm 4 Maneouvre the mechanism to free the winder spindle from the door and to disengage the upper sliding bosses of the scissor arms from the window lift channel and the lower sliding boss of the secondary arm from the static reaction channel 5 Withdraw the mechanism from the door 6 Before fitting a lift mechanism lubricate the three slider bosses and the sector teeth with Century Luplex 2 grease or similar Fit the mechanism 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 piv
127. injector is indicated vii To check that the pump has sufficient reserves of delivery for full demand conditions progressively clamp off the return hose with the pump running The pressure should increase by approximately 2 bar CAUTION Only clamp the return hose momentarily and observe the gauge to ensure pressure does not exceed gauge capacity 2000 01 Page 21 E Lotus Service Notes Section EMN 22 The fuel rail feed and return hoses equipped with push fit connectors to allow easy powertrain moval The feed line connector is colour coded orange and the return line connector green Note that the feed line should not be opened without first carrying out the fuel pressure relief procedure detailed above With the system depressurised cut the safety tie wrap from the connector collar and use an absorbent cloth to collect fuel draining from the pipe before pressing the collar into the connector and separating the joint Clean the pipe spigot and lubricate with a light spray of WD40 or similar before remaking the joint pressing firmly together until full engagement is indicated be an audible click Check security by pulling and twisting the joint To guard against any possibility of accidental release fit a small tie wrap 075 60382 around the release collar as shown Fuel feed hose push fit connector orange Fuel return hose push fit connector green Tie wrap fitted around release coll
128. into the damper mount tapping block Torque tighten to 45 Nm If no longerons are fitted to the subframe fit the subframe to the chassis and then fit the longerons to the subframe as follows Fitting rear longerons 1 Ensure that at each side the top surface of the subframe is free of zinc flashing including the outside top lip ofthe subframe Dry fitthe longeron to ensure that the channel in the extrusion fits onto the outside edge of the subframe with the longeron lying flat on the subframe top surface The damper mounting tapping blocks may be fitted before the longerons for easier access or alternatively to ease fitment of the longerons the tapping blocks may be fitted afterwards by feeding down the inside of the longeron 2 Clean the mating surfaces on the subframe and longeron using Betawipe VP 04604 A082B6150V as directed in sub section BM 5 3 Primethe whole of the mating faces of the subframe and longeron with Betaprime 5404 A082B6337V as directed in sub section BM 5 4 Apply a zig zag bead of Betaseal 1701 A082B6281F or Betamate E2400 A082B8415V to the primed surface of the subframe as detailed in sub section BM 5 Page 5 2000 02 Eb Lotus Service Notes Section AF 5 Hook the longeron over the edge of the subframe and onto the adhesive and slide fully forward until aligned with the rivet holes and roll over bar brace fixing hole in the tapping block If an aluminium boot floor is used i e pre boo
129. key head with ignition either on or off Mobilisation will be acknowledged by the tell tale being extinguished io Alarm 272 telltale Geen 2000 03 Arming the Alarm Remove the ignition key and check that the doors tailgate and front bonnet are closed Press the transmitter button for about two seconds This command will be acknowledged by Two flashes of the hazard warning lamps The tell tale ahead of the gear fever lighting and blinking off once a second After a set up period of 25 seconds has elapsed the tell tale will go out and blink on once a second 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 tailgate or front bonnet is not fully closed four beeps will be heard as warning If still open after 25 seconds the alarm will be armed with that switch excluded from the circuit After arming the system a period of at least 25 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 Opening a door tailgate or front bonnet Movement detected within the cockpit Energising the ignition circuit hot wiring Interruption of the vehicle battery power supply When triggered the electronic siren will sound and the hazard warning lamps will flash f
130. laws with which drivers should familiarise themselves instrument Illumination A small button is provided on the steering col umn shroud between the ignition switch and steer ing wheel by which the brightness of the instrument illumination may be adjusted To cycle through the four levels 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 Cigarette Lighter A cigarette lighter is fitted in the trim shroud ahead of the gear lever and is operative at all times To use the lighter press the centre button of the knob to activate the heating circuit When the element has been sufficiently heated which takes only a few moments the button will spring back out The lighter may then be withdrawn for use Care should be taken when handling the hot lighter to avoid contact other than with its target An illumination ring around the lighter is backlit red when the lights are switched on WARNING Do not leave small children unat tended in the car since careless use of the ciga rette lighter could be dangerous COLUMN SWITCHES amp HORN Headlamp Dipswitch Flasher Turn Indicators The steering column left hand lever switch con trols the headlamps main beam dip headlamp flash and turn indicators Headlamp Dipswitch To switch on the headlamps press the master lighting switch in the fascia out board of the steer
131. 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 If necessary unclip the slip ring from the steering wheel boss and withdraw with the horn lead Withdraw the column bearing preload spring 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 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 some compromise to track rod lengths may have to be made To arrive at the optimum setting proceed as follows Note that the only two splined joints in the steering system which allow a choice of position are the lower u j to rack pinion shaft and the steering wheel to column Page 3 E Lotus Service Notes Section HE 1 Set the front wheel alignment to specification with equal track rod lengths see sub section CG 2
132. located in the rear luggage com partment Data Link Connector The Lotus Check tool allows the following operations to be performed PRE TEST This is used to check whether any faults have been detected since the last pre test TEST This runs a test sequence for various engine management components LIVE DATA This programme enables current readings from various sensors to be displayed or printed PROG Applicable only to VVC models allows matching of engine and security modules after unit replacement TUNE Applicable only to VVC models checks and calibrates certain components Contents of the Lotus Check Too T000T1346 The Lotus Check Tool 000 1346 is supplied in a plastic case and contains the following items Scanner Tool with LCD display panel Printer Power Harness Adaptor Harness MEMS 1 9 Programme Card MEMS 2 Programme Card 5AS Security Programme Card Security Module Dongle Instruction Booklet dee 2000 01 E Lotus Service Notes Section EMN Adaptor harness plugged into DLC MEMS 1 9 amp switched to Power or MEMS 2J MEMS harness programme Printer Connect to battery Scanner tool To connect the equipment proceed as follows i Plug the power harness into the scanner too and the printer ii Insert the MEMS 1 9 standard engine or MEMS 2J VVC engine programme card into me scanner tool slot label uppermost iii Open the front and rea
133. m dn ei tw Oe Hu coe SS Aum meme B Ve HOJIMS 1008 2 o S T o x T i F z o es a En 4 4 DO Lo 4 4 C M Z El SE pias 5 id 44779 Md Si EE fe gt m 1 pode om zd d WHY Ty 2 i m ced Y i t LN3WAYLISNI E 3 a id l H eg EN Med gt l v Eq eI S o 09 2078 id mu MEE IINE ERES 6 5 i il ta o yt 5 a a Gen teg S gt lt lt e vol s d E g x 2 21 2 f g Se ZE v2 9 p Spec ra E a UE 5 5v2 2 Lotus Service Notes Section MN E STOP amp REVERSE LAMPS FUSES OX BATTERY gt e IGNITION START DROP OUT D gt FUSEBOX IGNITION tUNFUSEDI gt iis IGNITION FUSE DD gt 3 She gt INSTRUMENT PACK SEE SHEET 10 SE c TO HORN RELAY N gt 70 DIAGNOSTIC LONNECTOR SHEET 3 a t E 5 a 5 1 s 3 5 amp e 1 H z a 5 dE ae i RHC TA N REVERSE LAMPS USED A SIAN TEE CARS GNLY v KE Aa d ter
134. may be removed For road use the screen should be retained legal requirement but a procedure is included to modify the screen mounting to allow for easy fitment of the tonneau cover Fitting Procedure 1 Remove the passenger seat slide the driver s seat fully forwards and remove the cover from the rear bulkhead electronics box 2 Remove the rear screen For race use use grommets to blank off the screen fixing holes in the bulkhead 3 If the screen is to be retained Bond 5 x 12 big head stud A082W5128F into the two screen fixing holes in the bulkhead electronics box from the inside in the screen mounting bracket drill a 6mm diameter hole 9mm from each of the two fixing stud positions towards the rear edge of the bracket Cut the studs from the bracket and grind flush Paint the underside of the bracket black To fit the screen locate the screen bracket onto the two studs and secure with the plastic wing nuts A111W3146F Wing nut A111W3146F Drill new holes Big head stud A082W5128F b314 Page 44 Lotus Service Notes Section XA 4 Push the tonneau half round dash section into place below the windscreen and above dash Hold in place whilst marking each A post for the socket position Remove tonneau and drill a suitable hole in each screen pillar for the self tapping press stud socket Fit the two sockets 5 Fitthe tonneau to the screen pillars and pull tight into the roll hoop centre gap M
135. mm which differs from other sport variants due to the increased wheel diameter Standard Elise suspension links and hub carriers are used Geometry Mid laden ride height for geometry check front 112 mm below front end of chassis siderail rear 122 mm below rear end of chassis siderail Steering axis inclination 42 nominal Castor 3 8 0 2 side side 0 2 Camber 0 5 0 1 02 max side side 0 2 Alignment 0 2 mm toe out overall 0 2 mm 0 REAR SUSPENSION The Exige is fitted with the Elise Sport suspension package which includes adjustable spring platform Koni dampers with Exige specific springs Standard Elise wishbones and integral stud type toe links are used in conjunction with standard Elise forged steel hub carriers The specified mid laden ride height of 112 122 mm differs from other sport variants due to the increased wheel diameter For optimum rear bump steer set up information refer to sub section XA 8 Geometry Mid laden ride height for geometry check front 112 mm below front end of chassis siderail rear 122 mm below rear end of chassis siderail Camber 2 4 x02 max side side 0 2 Alignment 1 2 mm toe in each side 0 2 mm 0 max side side 0 2 mm EXIGE E ENGINE The engine is based on the Rover 1 8 litre K series unit and is reworked in a similar way to the VHPD 190 race version but tuned for road use Output of the engine is as follows Max powe
136. mounted in the radiator air intake aperture are activated The headlamps will default to the off condition whenever the ignition is switched off Rear Fog Lamp Switch Asingle fog guard lamp is fitted centrally on the muffler shield and is operative only in conjunction with the headlamps The fourth switch down in the cockpit central divide operates the fog lamp with an amber tell tale icon in the tachometer face indicating when the lamp is functioning 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 lamp can cause distraction and discomfort to following traffic The rear fog lamp circuit is designed to switch off automatically whenever either the head lamps or the ignition is next turned off requiring that the switch must be pressed again to re activate the circuit Heated Windscreen Switch The front windscreen is equipped with electrical heating elements in order to provide a defrosting facility for use in extreme conditions Page 24 EG Lotus Service Notes 340R The heating of the front windscreen is selected by the lower most switch in the cockpit central divide The Switch is operative only when the engine s running with a yellow tell tale icon in the tachometer face indicating when the circuit is active The heating elements place a high demand on the vehicle electrical system such that circuit sho
137. optimum engine protection with the following two products being specifically recommended Mobil One 5W 50 Castrol Formula RS 10W 60 A maintenance schedule for the 340R is available under part number LSL382 Page 46 E Lotus Service Notes 340R MAINTENANCE SCHEDULE ELISE 340R Date Owner s Name Vehicle Vehicle Registration No entume ete Recorded Mileage Months Since Last Service Job ster EXPLANAIORY NOTES In order to maintain warranty validation and help ensure proper safety emissions performance and depend ability of the vehicle Lotus Cars Ltd requires that the vehicle be serviced in accordance with this schedule Each service should be performed either within 1 000 miles 1 600 km of the distances stipulated or within one month of the anniversary of the previous service whichever first occurs Any necessary repairs should be completed without delay For vehicles frequently used on closed circuit tracks or driven in competitive condi tions higher levels of servicing will be required A cross X in the following table indicates an operation to be performed The corresponding box should be ticked 7 when the operation has been satisfactorily performed or the X circled if extra work and time is required The approval of
138. panel Cleaner primer amp re activator Betawipe 4000 Lotus part no 082 6355 Adhesive Betaseal 1701 Lotus part no A082B6281F 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 00021071 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 Page 6 CS Lotus Service Notes Section BM 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 suffici
139. pip and notch engaged Secure the steering wheel spacer ring to the locking ring with six countersunk screws using a suitable thread lock Fit the steering wheel to the spacer ring with six countersunk screws using a suitable thread lock Connect the two leads to the new horn push red to centre black to side and press the button assembly into position Fit the hub spacer ring to the splined hub using four caphead screws and suitable threadlock with the eyelet of the new horn extension lead beneath one of the screw heads Fit the horn slip ring carrier to the splined hub feeding the two wires through the hub and spacer ring Ensure that when the splined hub is fitted to the column the turn indicator cancelling vane is on the left hand side Check that the column bearing preload spring is fitted onto the column before fitting the splined hub with the match marks aligned Fit the column nut and tighten to 25 Nm Connect the horn lead spade connectors to the spigot hub and insulate with the sleeves provided Fit the spigot hub to the hub spacer ring with the notch on the hub periphery aligned with the TOP mark on the reverse side of the splined hub and secure with the six countersunk screws using a suitable thread lock Fit the steering wheel onto the spigot hub and check the operation of the key barrel lock horn button and indicator cancelling mechanism Illustration overleaf Page 31 Lot
140. piston return spring onto its seat on the front piston and carefully insert the front piston assembly into the cylinder taking great care not to damage the lips of the forward facing seals Fit the rear piston assembly into the cylinder again taking great care not to damage the lips of the forward facing seals Using a rounded end drift press the piston against its spring to enable the stop washer and retaining circlip to be fitted into the end of the cylinder Page 11 Lotus Service Notes Section JH 15 16 18 19 20 21 Thinly coat the two reservoir spigots and sealing grommets with ATE Brake Cylinder Paste or ATE Brake Assembly Spray or similar and insert the grommets into their locations in the master cylinder body Fit the reservoir to the master cylinder with the two spigots fully inserted into their grommets Ensure that the cap is positioned towards the rear with the clutch fluid take off on the left Lubricate the pushrod boot with rubber grease before fitting onto the end of the master cylinder with its lip correctly located in the groove Fit the master cylinder assembly to the pedal box inserting the brake pedal pushrod through the master cylinder boot to engage into the hollow of the rear piston Retain with the two M8 bolts and tighten to Nm 22 Ibf ft Check the pushrod length The pushrod length must be adjusted to apply a slight preload to the master cylinder with the pedal released Too much
141. problem Circuit low input Circuit high input Too high Too low Not closing Not opening EG Lotus Service Notes 340R Intake System amp Resonator Valve A new short intake manifold assembly incorporates individual inlet tract butterfly throttles operated via cable quadrant between cylinders 2 amp 3 A carbon fibre airbox bigger still than the Sport 190 version is supplied with air via large diameter trunking terminating at the left hand lower corner of the engine bay Incorporated in the intake trunking at the entrance to the airbox is a butterfly valve which is controlled by the engine management system and is designed to suppress resonant intake noise under certain engine operating conditions The valve is sprung open and is closed by a vacuum actuator supplied via a pair of solenoid valves mounted on the LH side of the engine bay The solenoid valves are controlled by the engine management ECM which is programmed to close the valve when accelerating with wide throttle through the lower gears at about 30 40mph The flap capsule is connected to a vacuum charging solenoid valve which either ventilates the the capsule or connects it to a vacuum locking solenoid valve The locking valve either seals the charging valve or connects with the manifold vacuum supply via a reservoir mounted on the roll over bar back stay MAP sensor Vacuum reservoir Locking solenoid Resonator valve valve actuator Charging solenoid valve Resona
142. rear timing gear j 16 X DESCRIPTION AND OPERATION ENGINE Fosse OPERATION The K Series engine is built up from aluminium castings bolted together These consist of three major castings the cylinder head cylinder block and a bearing ladder which is line bored to provide the main bearing bores Attached to these are three minor castings above the cylinder head the camshaft carrier and the camshaft cover Below the bearing ladder is an oil rail Each of the ten cylinder head bolts passes through the cylinder head cylinder block and bearing ladder to screw into the oil rail This puts the cylinder head cylinder block and bearing ladder into compression with all the tensile loads being carried by the cylinder head bolts When the cylinder head bolts are removed additional fixings are used to retain the bearing ladder to the cylinder block and the oil rail to the bearing ladder K8 engine The cross flow cylinder head has two valves for each cylinder and the spark plugs set at an angle The inlet ports are of equal tract designed to ensure a balanced mixture throughout the speed range to improve combustion and reduce exhaust emissions The single overhead camshaft operates both inlet and exhaust valves via hydraulic tappets and is driven from the crankshaft by a timing belt Belt tension is maintained by a spring loaded tensioner The camshaft is retained by a one piece camshaft ca
143. reduce the effective diameter Lower Wishbone Inboard Pivots amp Early Type Anti Roll Bar Mountin Front leg Rear leg Flanged Bonded reinforcement spacer tube plate Bonded inserts Bonded inserts Anti roll bar Clamp pivot block bolt Anti Roll Bar Drop Link Lower wishbone Anti roll bar drop link Anti roll bar 1998 02 Lotus Service Notes Section CG Cars built from VIN W 3039 March 98 use bonded rubber type pivot bushes and alloy clamp brackets to secure the re shaped anti roll bar to the chassis front face Washers welded to the bar bear against the inner sides of the bushes to provide lateral location Castrol LMX rubber grease or equivalent should be used when fitting the rubber bushes onto the anti roll bar Spacer plate Clamp bracket fixing screw Clamp bracket Pivot bush Anti roll bar It is possible to update an early car to the later specification by drilling the chassis front face to accept the new clamp brackets and substituting the new parts including the reshaped anti roll bar Fettling of the crash structure will also be required to provide clearance for the higher mounting position of the new bar Note that smaller washers are used on the clamp bracket upper fixing bolts in order to clear the joint ridge in the chassis extrusion 63 5 mm el 52mm Gg Wishbone pivot hole 10 New a r b mounting holes CG 4 SUSPENSION DISASSEMBLY ASSEMBLY
144. remove all soap from the fabric and to prevent streaking on the car bodywork 6 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 2 3 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 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 the normal washing a polish with a good quality liquid polish will restore the original lustre of the paint film Higher gloss of the paint film and added protection against contamination can be obtained by wax polishing but it must be remembered that a wax polish can only be used successfully on a clean surface and that the previous application must first be removed with white spirit or a liquid polish cleaner before re waxing Ventilation Water lying on the paint surface for lengthy periods will penetrate the paint film Although the effects will not be visible immedia
145. reverse plane If any adjustment to the crossgate cable is made the stop bolt adjustment should be checked For access to the lever mechanism the gear lever knob and shroud must first be removed unscrew the knob remove the screw each side of the shroud and lift the shroud over the lever The nominal stop bolt setting of 12 mm should be adjusted as necessary to provide minimal clearance when the lever is operated in the 5th reverse gear plane as is consistent with satisfactory gear selection Crossgate bellcrank lever Crossgate stop bolt EN DN Crossgate cable Gearlever Replacement For access to the gear lever assembly unscrew the gear knob remove the single screw each side of the gear lever shroud and lift the shroud over the lever To remove the gear lever Remove the E clip from the bellcrank lever pivot Unsnap the select cable socket from the gear lever ball Remove the three screws securing the gear lever housing to the mounting bracket disengage the bellcrank Page 4 NE Lotus Service Notes Section lever pivot and crossgate spigot bush and withdraw the housing and gear lever assembly To re assemble Fit the pivot socket gasket into the gear lever housing followed by the top smaller section of the pivot socket Apply Dow Corning Molykote 33 Medium silicone grease A111F6016 to the gear lever pivot ball and to the crossgate spigot ball before fitting the lever into the housing followed by the lower
146. section of the socket Snap the plastic bush onto the lever crossgate spigot ball Locate the bellcrank lever pivot into the gear lever housing and retain with the E clip Fit the crossgate spigot into the bellcrank lever and locate the gear lever housing onto the mounting bracket Fit and tighten the three gear lever housing screws and snap the select cable socket onto the bottom of the gear lever Check gear linkage operation and adjustments before fitting the pivot ball dust shield over the lever and refitting the shroud NOTE To avoid the requirement to replace the retaining clip bush do not disconnect the crossgate cable from the belicrank lever unless necessary Bellcrank pivot bracket Bellcrank tie rod Dust Gear lever shield housing Crossgate 8 bellcrank Gc H Gear lever pivot socket CH Outer cable retention clip AN C c Mounting bracket spacers Gear lever mounting bracket Parking brake lever mounting bracket Page 5 Lotus Service Notes Section FH 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 Remove the single screw securing the parking brake trim to the rear bulkhead and ease the panel over the lever Unclip the crossgate cable from the bellcrank lever or
147. see below must be maintained Although the transmission casing was revised for the type seal to include a machined face for the seal flange to butt against if neces Steel insert sary a B type seal may be fitted in an earlier type casing Inboard C V joint With the introduction of the B type seal a corresponding change to the C V joints was made in order to provide clearance for the steel insert in the seal with an identification groove being added to the joint s outer sur face for ready reference The new joint may be fitted to both new and old type transmis sions seals but the old type joint must not be fitted into a new type transmission or B type seal Identification groove Page 7 S y Lotus Section FH Driveshaft Replacement Removing a driveshaft 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 the transmission drain plug and drain off approximately 1 litre of oil into a clean container for re use 2 Remove the rear road wheel 3 Before attempting to release the driveshaft hub nut first use a punch to knock the distorted end of the nut clear of the driveshaft slot Apply the parking brake and release the driveshaft hub nut 4 Remove the wheel speed sensor from its plinth to prevent damage during driveshaft removal 5 Toallow the hub ca
148. sided tape and steel U clips to a vertical metal flange bonded to the door outer top edge The door glass must be withdrawn from the door see sub section BN 9 before access to the seal fixings is available Door glass Inner seal Outer seal Inner door shell Outer door shell Metal flange Metal flange U clip Page 17 CS Lotus Service Notes Section BN To fit a new outer seal 1 Compare the new and old seals and if necessary cut additional slots in the new seal to allow it to be formed to the profile of the door top surface Chamfer the lower rear corner to allow the seal to fit correctly in the door 2 Clean the flange on the door shell and the vertical mating face on the new seal with Betaclean 3900 A100B6008 and apply PP Primer 3842 A082U6199V to both surfaces 3 Apply double sided tape to the whole length of the flange and a thin bead of black Silastic under the outside lip of the seal Fit the seal onto the flange with the outer lip bedded against the door top edge and secure with eight spring steel U clips Door Weatherstrip A hollow section rubber weatherstrip is bonded onto the door aperture to seal against the door shell A stiffener buffer is inserted into the seal in the area of the latch striker pin and a small D section weir is stuck to the front shut face of the door to provide optimum sealing of this area Before fitting a new weatherstrip ensure first that the foam rubber tapered pac
149. solvent Ensure reference marks are not erased 1 Clean timing gears check gear teeth for damage and drive pin slot for wear replace gears as necessary OVERHAUL 47 NGINE alves and springs remove 1 Support cylinder head clear of valves use hollow drift and tap each spring cap to free collets 2 Position cylinder head on its exhaust manifold face NOTE K16 engine Remove inlet valves with cylinder head in this position BRM 3627 NOTE K16 Non VVC cylinder head illustrated 6 Remove spring cap and valve spring 7 Remove valve NOTE K16 Non VVC cylinder head SC illustrated 3 Using tool 18G 1519 and adapter 18G 1519 1 compress valve spring 4 Remove 2 collets from valve stem using a magnet 5 Remove tool 18G 1519 48 OVERHAUL ENGINE Foose 8 Using 18G 1577 remove and discard valve stem seal 9 K8 Repeat above operations to remove all remaining valves 16 Repeat above operations to remove remaining inlet valves CAUTION Retain valves and springs in fitted order K16 10 Position cylinder head on its inlet manifold face 11 Repeat above operations to remove exhaust valves and valve stem seals CAUTION Retain valves and springs in fitted order Cylinder head cleaning 1 Clean sealing surfaces on cylinder head and camshatt carrier Use foam action gasket remover and a plastic scraper DO NOT USE A METAL SCRAPER ON SEALING SURFA
150. specification with Service limits where applicable REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Rover recommended parts are used Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories Safety features and corrosion prevention treatments embodied in the car may be impaired if other than Rover recommended parts are fitted In certain territories legislation prohibits the fitting of parts not to the manufacturer s specification Torque wrench setting figures given in this Manual must be used Locking devices where specified must be fitted If the efficiency of a locking device is impaired during removal it must be renewed The Terms of the vehicle Warranty may be invalidated by the fitting of other than Rover recommended parts All Rover recommended parts have the full backing of the vehicle Warranty Rover Dealers are obliged to supply only Rover recommended parts INTRODUCTION 1 INTRODUCTION SPECIFICATION Rover are constantly seeking to improve the specification design and production of their vehicles and alterations take place accordingly While every effort has been made to ensure the accuracy of this Manual it should not be regarded as an infallible guide to current specifications of any particular component or vehicle This Manual does not constitute an offer for sale of any partic
151. spring pin accessible via a hole in the column switch carrier and withdraw the lock barrel 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 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 Remove the pinch bolt securing the upper universal joint to the intermediate column Remove the two fixings for the in strument pack mounting brackets and remove the instrument pack and cowl assembly after unplug ging the single harness connec tor Unplug the Lucas 5AS module and support the column before removing the two bolts securing the column upper mounting flanges captive nuts Remove the Lucas module and bracket and release the single lower column fixing Withdraw the column assembly from the scuttle and off the inter mediate steering column Refit the column in reverse order to removal with the following notes The groove for the pinch bolt al lows 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 assem bly
152. standard engines using grouped injection 1 with 4 2 with 3 itis not necessary to determine which cylinders are on the firing and which on the exhaust stroke On the VVC engine using fully sequential injection an additional signal from the camshaft position sensor is required to determine the correct injection and ignition sequence To prevent damage from engine overspeed on acceleration the ECM will implement fuel cut off at en gine speeds above approximately 7 000 rpm by inhibiting the earth path for the injectors Fuel is progressively reinstated as engine speed falls Faults in the crankshaft sensor or circuit may be indicated on the scanner tool by a 0 display during cranking On standard engines sensor pin no 1 connects to ECM terminal 32 and sensor pin 2 to ECM terminal 31 Sensor resistance is 1 3 kohms Fixing screw torque 6 Nm EG Lotus Service Notes Section EMN The ECM requires a coolant temperature input signal in order to increase fuel delivery and maintain driveability during the cold running and warm up phase The signal from this sensor is used for many different parameters within the engine management system to control and switch various components dependent on engine temperature The sensor is a thermistor a resistor which changes value with temperature mounted in the outlet junction pipe at the flywheel end front side of the engine Note that the ECT sensor has a brown body and harness connector and is mounted
153. supplied only as a kit including the associated conical spacer and larger diameter shim washers Note Each toe link uses a right hand threaded joint on one end and a left hand threaded joint on the other and that whilst all cars are factory built with the RH thread outboard the orientation of the link is not important and may become reversed in service Aiways check the thread handing before ordering parts When the earlier type joint is being replaced by an integral stud type in order to ensure that correct assem bly of the joint is always possible both LH and RH threaded joint kits include the outboard fixing spacer and shim washers which are not required for inboard applications Assembly procedure toe link outboard fixing integral stud type joint Thoroughly clean the stud before fitting through the conical spacer small end first then through the bump steer shim washers and fi nally through the hub carrier Fit the plain washer and a new Nyloc nut and torque tighten to 45 Nm Bump steer shim washers Conical spacer Page 10 1999 0 1 Thoroughly clean the stud before fitting through the chassis subframe and wishbone rear bush Fit the plain washer and a new Nyloc nut and torque tighten to 45 Nm only with the car at ride height DE 5 REAR HUB BEARINGS Each rear hub carrier houses a sealed dual taper roller bearing with a split inner race The hub is pressed into the bearing and the outb
154. the bonding between the cleaned and or activated surface and the adhesive compound Supplied in 250 mi aluminium con tainers of component A and component B 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 Re place 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 primer 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 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 in consistent film build Replace the felt pad if moisture absorption results in hardening Never return unused Betaprime back into the aluminium container BETASEAL 1701 A082B6281
155. 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 There is no charge to the vehicle owner for the labour content of the After Sales Service Only materials used will be charged 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 Odometer Reading Time Period Service Type 1 000 to 1 500 miles To be performed within 12 months of After Sales Service 1 500 to 2 500 km vehicle date of sale 6 000 miles 10 000 km Or 12 months since last service 12 000 miles 20 000 km 18 000 miles 30 000 km 24 000 miles 40 000 km 30 000 miles 50 000 km 36 000 miles 60 000 km m 42 000 miles 70 000 km 48 000 miles 80 000 km 54 000 miles 90 000 km 60 000 miles 100 000 km 66 000 miles 110 000 km O gt uU O gt gt gt 72 000 miles 120 000 km NS ee Page 47 3405 SERVICE OPERATION DESCRIPTION After Other a Sales A B C intervals 1 Fit protective covers to seats footwells steering wheel amp rear body X X X X 2 Renew engine oil amp filter Inspect engine amp transmission for oil leaks 4 Check transmission oil Even 5 Wash or replace air cl
156. the damper using a suitable spring compressor to allow the spring collar retaining circlip to be released from its damper body groove Note that the springs were changed in June 98 from parallel black to barrel shaped graphite for improved spring stability For parallel Springs the lowermost spring abutment circlip groove is used highest ride height whereas the barrel shaped springs use the top groove See also sub section DE 7 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 On the early type anti roll bar mountings ensure that each mounting block is fitted with a flanged steel Sleeve from the rear end before inserting the lower wishbone pivot bolt Smear the shank of each pivot bolt with PBC grease Apply Permabond A131 A912E7034 to the threads of any bolts tapping into an alloy extrusion Note that the lower swivel joint plinth is handed but can only be fitted to the hub carrier in its correct hand and orientation Tighten the ball pin into the plinth before fitting the plinth to the hub carrier Coat the joint faces of the hub carrier with the lower swivel joint plinth and with the steering arm with Duralac MSDS anti corrosive jointing compound A111C6017 and assemble whilst the compound is still tacky 1398 03 reget Lotus Service Notes Section CG Take care to ref
157. the intake air duct approx 50 mm behind the towing strut Mark up the fixing holes in the floor of the duct and drill M6 clearance holes Mount the cooler using the M6 fixing screws and washers with the pillar nuts between the duct floor and cooler 5 Connectthe cooler hoses to the oil filter housing with the 45 return hose union fitted to the housing right hand port and the swept 90 union on the feed hose connected to the left hand port Take care to route the feed hose with its heat protective sleeving away from the exhaust downpipe and secure to the water rail at the front of the engine bay Route both hoses against the bulkhead outboard of the fuel filler hose and through the engine bay RH air intake aperture on some early cars it may be necessary to cut an aperture in the side closing panel Ensure that both hoses are fitted with convoiute protective sleeving in vulnerable areas especially through the air intake aperture 6 Route the hoses against the upper part of the cockpit closing panel beneath the coaming and secure with P clips positioning the clips to allow access to the topshell fixing studs Continue routing against the windscreen buttress and RH top rear corner of the radiator duct clipping as required Take care not to inhibit topshell fitment or headlamp access Feed the hoses through the air duct holes and fit the grommets Connect to the oil cooler using two spanners to prevent the cooler unions being twisted
158. the lid and consists of a striker pin clamped to the lid plinth with a tapping plate and locknut and a latch slider plate mounted on a composite carrier bonded to the rear clamshell A bowden cable con nects to the slider plate by a clamp screw and terminates in a release handle mounted in the rear shut face of the driver s door aperture In the event of cable breakage access to the latch is available after removing the driver s side rear wheelarch liner Engine lid release handle Es24 Adjustments The height of the rear edge of the panel is controlled by the setting of the striker pin which may be screwed up or down as required The height of the front edge is controlled by the number of shim plates fitted between the hinge blade and the panel with slotted holes in the blade allowing for positional adjustment of the panel Ka A Aen gt gt es 522225 525655222 552255225255 Engine lid plinth Shim plates Hinge blade 99 Clamshell fixing Thrust washers Pivot screw Pivot bush Hinge bracket ks Engine Lid Hinge A hinge bracket with two pivot lugs is bonded and rivetted to the rear side of the cabin rear bulkhead with an integral reinforcement bracket picking up on two adjacent clamshell fixings The alloy hinge blade is bolted to the lid via three M6 screws with tapped bobbins laminated into a plinth on the underside of the engine lid panel A tube welded to the front end of the hing
159. the rearward biased top wishbone pick up on the chassis rear subframe and converge outboard 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 forward biased 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 rear subframe The outboard end of the wishbone houses another swivel ball joint fixed via a forged steel plinth similar to that used on the front suspension to the bottom of the hub carrier by four bolts The adjustable length double ball jointed toe control link shares a chassis anchorage with the rear of the lower wishbone and picks up on a rearward extension of the hub carrier The spring damper unit is fitted with the damper rod lowermost to minimise unsprung weight and acts between the outer end of the lower wishbone and a steel clevis bracket bolted to the rear end of the chassis main side rail Certain components are common with the front suspension and include top and bottom swivel joints hubs and hub bearings and some wishbone pivot bushes DE 2 GEOMETRY amp 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 geome
160. the standard vehicle warranty will not apply after the fitment of off road or competition oriented parts XA 2 190 VHPD ENGINE The 190 VHPD Very High Performance Derivative engine is designed for motorsport track use only and may not comply with emission regulations The unit is based on the same 1 8 litre Rover K series block as the standard engine but with a revised cylinder head featuring new inlet and exhaust camshafts solid tappets and new throttle bodies providing individual throttle butterflies for each cylinder and a competition type oiled foam air cleaner The engine bottom end includes forged pistons strengthened connecting rods and crankshaft and a lightened flywheel A reprogrammed ECM is an integral part of the package The preferred fuel is 98 RON unleaded Super Unleaded although 95 RON is useable Oil recommendation is Mobil 1 5W 50 fully synthetic after running in on a good quality mineral oil Output Max power 190 ps 7 500 rpm Max torque 189 Nm 5 600 rpm The engine is supplied only as a complete assembly for competition use and does not carry the normal vehicle or parts warranty Included in the engine package are Engine harness and new ECM with matched security 5AS module Exhaust manifold unchanged Inlet manifold throttle bodies and competition air filter Air filter oil aerosol Fuel rail and injectors Alternator and auxiliary belt unchanged Lightened flywheel no clutch
161. through each strut end spigot Tighten the M12 U bracket to A frame fixing bolt to 77 Nm and the M8 end spigot bolts to 22 Nm 10 Fitthe 6 point seat belt harnesses as detailed in sub section XA 2 Page 12 Section jurod amp iueu 13 a Lotus Service Notes dooy Jamo uojsuadsn 0S X Sw JoBids pue E Lotus Service Notes Section XA XA 5 HAND HELD FIRE EXTINGUISHER A111T0002 ecommended Fitting Instructions It is recommended that this extinguisher is mounted ahead of the passenger seat fixed to the cockpit floor crossmember as detailed below 1 Mark the positions of the two fixing holes in the crossmember as shown in the diagram 2 Drill the two holes 9 0 mm diameter through only the top surface of the crossmember 3 Insert the two Rivnuts and use an M6 threaded puller tool or appropriate M6 slave screws to crimp the two Rivnuts into position 4 Fit the extinguisher mounting bracket using the two countersunk M6 screws provided and clip in the extinguisher Chassis side rail Extrusion overlap edge 23 mm Drill both holes ER em 9 mm diameter j 123 mm 1 509 14 Lotus Service Notes Section XA XA 6 PLUMBED IN FIRE EXTINGUISHER KIT A111T0004S The illustration overleaf shows the suggested layout of this fire extinguisher kit for use in the Lotus Elise The bottle is sec
162. thrust washers and needle roller bearings located at each end of and between the side gears whilst on Type B differentials a combination of thrust washers and friction washers is used When both front wheel speeds are equal then the frictional loads imposed by the element gears on the side gears are also equal However when the drive resistance on a road wheel is reduced through loss of traction then a torque imbalance is created less torque being required to tum the wheel with the highest speed This torque imbalance is sensed by the differential and results in a lowering of the friction imposed by the element gears on the side gear MANUAL GEARBOX 0 0 driving that particular wheel This causes a reduction in wheel speed until a point is reached where traction is restored the torque required to turn both wheels is equal and both wheels are rotating at the same speed DESCRIPTION AND OPERATION 7 MANUAL DESCRIPTION REVERSE BRAKE A reverse brake mechanism has been introduced to the PG 1 gearbox and is operated by the selector fork mechanism which stops the input shaft from rotating prior to the engagement of reverse gear and provides a quiet and smooth engagement of reverse gear providing the vehicle is stationary The reverse brake utilizes the 3rd 4th synchro hub for its operation The 5th reverse shift piece which is secured to the selector shaft by a roll pin and incorporates two g
163. to xcu chassis rear EE Matrix air feed Rubber strap Thead insert Page 7 Section To remove the matrix or blower fan unit the complete assembly should be removed from the chassis Remove the washer bottle battery and blower fan outlet ducting Label and disconnect the electrical leads to the blower fan Release the spring clip securing the outer control cable to the matrix moulding and unhook the inner cable from the flap lever Release the two hoses from the matrix inlet and outlet connections and immediately plug to reduce coolant loss Remove the four screws securing the matrix blower fan assembly to the chassis and withdraw the com plete unit Unhook the rubber strap to separate the matrix and mouldings from the blower fan unit Re assemble in reverse order to the above noting that on LHD cars a spacer is used between the fan housing and the rear of the chassis well Note that the control cable to the air blender flap is connected to the outermost hole in the flap lever arm Page 8 Lotus Service Notes Section PH ne AIR CONDITIONING H VEN N SECTION ELISE amp EXIGE 2000 M Y Sub Section Page General Description PH 1 2 Controls Operation amp Airflow Distribution PH 2 5 Vacuum Control System PH 3 9 A C Clutch amp Cooling Fan PH 4 12 Coolant Re circulation Pump PH 5 12 Refrigerant Handling PH 6 13 Refrigerant Pipework Precautions PH 7 14 Refriger
164. to design engineering specification with Service limits where applicable During the period of running in from new certain adjustments may vary from the specification figures given in this manual These will be reset by the Dealer at the First Service and thereafter should be maintained at the figures specified in this manual REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Rover recommended parts are used Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories Safety features and corrosion prevention treatments embodied in the car may be impaired if other than Rover recommended parts are fitted In certain territories legislation prohibits the fitting of parts not to the manufacturer s specification Torque wrench setting figures given in this Manual must be used Locking devices where specified must be fitted If the efficiency of a locking device is impaired during removal it must be renewed Owners purchasing accessories while travelling abroad should ensure that the accessory and its fitted location on the car conform to legal requirements The Terms of the vehicle Warranty may be invalidated by the fitting of other than Rover recommended parts All Rover recommended parts have the full backing of the vehicle Warranty Rover Dealers are obliged to supply only Rover recommended parts INTRODUCT
165. to full speed as an engine protection strategy T RE CIRCULATION PUMP In order to control engine temperature in conditions of heat soak after engine switch off a c cars are equipped with an electric pump to circulate coolant through the engine and prevent localised boiling The pump is mounted at the rear of the cylinder head in the radiator by pass circuit and when operating pumps coolant from the engine outlet elbow back into the engine at the thermostat housing A smaller flow will also occur through the radiator and heater circuits Pump Control Elise The re circ pump will operate with ignition off when coolant temperature as sensed by a thermal switch in the radiator feed pipe at the bottom front of the engine bay is above approx 100 A relay timer module mounted in the front services compartment limits the operating time to 20 minutes Exige The re circ pump is controlled by the engine management ECM and will operate the pump with ignition off at temperatures over 105 C off at 100 C as indicated by the engine coolant temperature sensor A timer function limits pump operation time to 20 minutes 2000 04 Lotus Service Notes Section PH PH 6 REFRIGERANT HANDLING The system is charged with 0 88 kg of refrigerant HFC R134a and the following precautions MUST ALWAYS BE OBSERVED 1 Onno account should refrigerant ever be discharged to atmosphere use refrigerant recovery recycling station
166. to start engine Engine immobilised YES e Switch on ignition f Apply immobiliser touch key to socket on steering column shroud g Try to start engine Engine starts YES h Stop engine i Turn siren on with the override key siren will sound and disarm the system with the transmitter key press the red button twice for 1 full second each time Transmitter Battery Replacement Each of the transmitter keys is powered by a 12V battery type GP23 With normal use these should last between 6 and 9 months To ensure continuity of trouble free operation it is recommended to replace both batteries at 6 monthly intervals 1 Split the transmitter case using a finger nail or blade in the indent provided in the case jointline 2 Pull out the battery and insert the new taking care to match the polarity marking 3 Snapthe case halves together Component Location The central processor unit CPU is mounted behind the passenger side fascia on the chassis scuttle beam with the aerial routed alongside the harness The buzzer unit is mounted alongside the CPU stuck to the top surface of the beam by a self adhesive pad Access to the CPU and buzzer unit is available after removing the passenger side dash panels see sub section BN 12 The siren including the override keyswitch is fixed to the top of the passenger footwell and the immobi liser module is mounted to the rear of the engine management ECM on the electrical services plate
167. to support legs on the fascia top two screws outboard of column and unclip the panel from the fascia Note the spring steel clips used along the top edge of the dash top extrusion to inhibit rattles Dash top extrusion Fascia top Plastic insert Spring steel clip panel e Dash centre extrusion Parts of bonded Dash lower extrusion chassis assembly b262 5 Release the heater controls and audio set if fitted from the dash centre panel and remove the four screws securing the panel to the dash lower panel two screws outboard of column If necessary de press the retaining tabs on the push switches to remove the switches from the outboard centre panel 6 Before removing the lower panel remove the coin tray at the bottom of each outer end of the panel by carefully peeling away from its double sided tape and withdrawing from the A post and sill top apertures Note that a bead of Silastic is used along the panel lower edge to inhibit rattles 7 fascia end finishers are are secured to the fascia top with Rokut rivets 8 Reassemble the dash components in reverse order to removal Page 24 Lotus Service Notes Section BN BN 13 WINDSCREEN The laminated windscreen is bonded to the composite frame using Betaseal flexible polyurethane adhe sive and uses a rubber finisher strip around its top and side edges Removal of the screen requires that the adhesive is cut using a suitable specialist tool
168. to the starter motor solenoid Oxygen Sensor Heater Relay Energised by the ECM to supply current to the oxygen sensor heating element The unit is mounted adjacent to the engine management ECM either at the left hand side of the rear luggage compartment on pre bootbox cars or on later cars at the rear of the engine bay on a tongue fixed to the rear subframe If any of the above functions are faulty the relay module should be replaced Pull the module off its mounting tongue and release the two harness connector blocks press the retaining clips On re assembly ensure the connector blocks are fully engaged by the retaining clips Pages 9290701 EG Lotus Service Notes Section EMN module S TE PR The MAP signal is fundamental to the calculation of air consumption and fuel calibration The ECM provides a 5 volt supply and earth path to the sensor which returns a voltage representing the manifold pressure On standard engines the MAP sensor is contained within the ECM and receives a signal from the intake plenum ahead of no 1 cylinder intake tract via a small bore rubber vacuum hose A liquid trap is incorporated into this line and is mounted on the right hand side of the engine bay aperture Faults with the MAP sensor require that the ECM be replaced When using the Lotus Check tool an atmospheric pressure of approximately 100 KPa should be dis played with the engine stopped and a lower value between 25 40
169. tube engine bay water rail to the water pump side of the thermostat housing Radiator by pass circuit The smaller of the two spouts on the cylinder head outlet elbow connects directly with the heater return pipework When the thermostat is closed the radiator return circuit is shut off so that water is forced to flow through the heater and by pass circuits thus ensuring optimum heater performance The header tank is mounted at the left hand front 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 bing pressure cap to raise the boiling point of the coolant to over 120 C The engine cooling radiator is of aluminium construction with plastic end tanks and is horizontally mounted at the front of the vehicle 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 A single mm diameter electric cooling fan is fitted to the underside of the radiator to supplement when required the ram air flow and a composite duct directs air exhausting from the top of the radiator through outlets incorporated into the front bonnet Separate coolant temperature sensors for the engine management system wh
170. valve 8 Modified exhaust valve 8 Valve collets 3 Inlet camshaft 1 Exhaust camshaft 1 Camshaft oil seal 4 Cam cover gasket 1 Cylinder head gasket 1 Blanking plate vac spigot 1 Inlet manifold stud 2 Exhaust manifold stud 5 Inlet manifold gasket 1 Exhaust manifold gasket 1 Upper lower manifold gasket 1 Screw 5 Manifold support strut 1 Screw 1 Screw 4 Spark plug 4 Spark plug cover green 1 Modified inlet manifold upper 1 Inlet manifold lower 1 Screw upper to lower manifold 5 Adaptor AIT sensor 1 Water outlet elbow gasket 1 Fuel return pipe 1 Boot bulkhead 1 1 Check parts supplied against above list 2 Referto Elise Service Notes manual section EE and remove the cylinder head If the car is fitted with an aluminium boot bulkhead remove the bulkhead 3 Remove from the old cylinder head the plastic inlet manifold assembly 4 Fromthe plastic inlet manifold assembly remove the following components for re use 1999 01 nage E Lotus Service Notes Section XA 10 11 12 13 14 15 16 17 Air inlet temperature sensor Fuel rail and injectors Idle air control stepper motor Throttle body and breather pipes Remove from the old cylinder head the following components for re use Cam belt tensioner spring pedastal bolt Rotor arm and anti flash shield Distributor cap and HT leads Water outlet elbow Assemble the new inlet manifold Fit the new upper inlet manifold
171. washers used on the upper bolt between the glass rear guide channel fixing bracket and the door beam and withdraw the door assembly off the beam Note that it is necessary to remove the drop glass inner waist seal before the glass may be withdrawn from the door Captive Door beam Beam to extension Door beam fixing bracket fixing extension bracket Door beam Door shellto Flange spreader extension plate bracket fixing When refitting the door remember to first fit the flange spreader plate onto the beam before mounting the door shell 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 It may be necessary to leave the tightening of the top rear fixing also secures the rear guide rail after the glass has been fitted and the position of the rear guide rail adjusted 2249 BN 9 DOOR GLASS GUIDE CHANNELS amp WINDER MECHANISM A manually operated door window scissor type lift mechanism is used in conjunction with two aluminium guide channels 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 t
172. with access to the screen lower edge available only after the rear end of the front clamshell has been released To Replace Windscreen Parts required Windscreen Finisher strip windscreen edging Betaseal Kit Plinth interior mirror mounting Loctite 7649 activator and Loctite 326 adhesive 24 Remove the wiper arm from its spindle and the interior mirror from its plinth 2 In order to allow access to the lower edge of the screen the rear of the front clamshell must be released At each side release the rear end of the wheelarch liner and remove the screw securing the clamshell to the front end of the sill At each side release the screw securing the bottom rear corner of the clamshell to the sill At each side release the screw securing the top rear corner of the clamshell at the base of the windscreen pillar Release the four fixings in the clamshell bonnet aperture gutter 3 Apply suction handles to the screen before using a pneumatic cutting knife such as Chicago Pneumatic s CP 838 Pneu Nife to cut the windscreen adhesive bead around the entire periphery of the screen Lift out the screen Cutting out screen using pneumatic tool Page 25 Lotus Service Notes Section 4 Remove old adhesive from the windscreen frame sufficiently to leave a consistent and flat surface for the new bond 5 Lay the new windscreen suitably supported on a protected surface inside uppermost and clean the whole of the ins
173. with temperature mounted in the outlet junction pipe at the flywheel end front side of the engine Note that the ECT sensor has a brown body and harness connector and is mounted horizontally This should not be confused with the water temperature gauge sender which is fitted in the same pipe but has a blue body and harness connector and is mounted vertically from below Low coolant temperature produces a high resistance whereas high temperature causes low resistance At normal running temperature the resistance will be approximately 300 400 ohms This data is also used to control the radiator fan which is switched on by the ECM at a rising coolant temperature of 102 C and switched off on falling temperature at 96 C Engine Coolant Temperature ECT sensor Brown Coolant temperature gauge sender Blue 900204 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 To replace the sensor disconnect the harness plug and position a container to catch the escaping cool ant when the sensor is removed Unscrew the sensor from the junction pipe Clean the threads of the pipe and sensor before applying Teflon tape to the sensor thread and screwing into the pipe Tighten to6 Nm Refit the harness plug and top up with coolant see Cooling Section KF If the ECM detects a coolant sensor open circuit a default value of 60 C will be s
174. 00T1276 or by applying a shock pull to joint body using a slide hammer with a forked end CAUTION Do NOT attempt to remove the inboard joint from the transmission by pulling on the driveshaft This action will cause the joint to become disassembled and may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive axial force is used Apply pressure only to the tulip or outer body of the joint Withdraw the inboard C V joint from the transmission and fit blanking plug TO00T13885 into the transmission to limit the amount of transmission oil loss From above Release the air cleaner mounting plate from the chassis and release the fuel filter mounting from the plate Withdraw the plate complete with air cleaner assembly Remove the header tank Disconnect the two hoses release the two fixing bolts and withdraw the tank Page 5 CS Lotus Service Notes Section EE 11 Release the clutch slave cylinder from the mounting bracket and support aside 12 Release the coolant outlet hose from the pipe at the front of the engine bay and release the pipe P clip from its bracket at the front of the engine Release the coolant return hose from the water rail at the left hand end of the engine and disconnect the heater return hose 13 Disconnect the throttle cable and purge pipe from the th
175. 03 zs Pano 7 Introduction Lotus Service Notes S ET NP ha E 2777 G 2 5 2 2 2000 03 Page 8 Eb Lotus Service Notes Section TDL TECHNICAL DATA ENGINE TION TDL M11 Page sivo rm coSed D DU S Ni 2 eS ios Head MP 2 Camshafts amp Valve Timing 22 2442 22 2 VC HE 2 Valve er TEEN 3 Seats x es EE 3 Valve SPringS EU I 3 Crankshaft ater o ad oae d c ede saec pue 3 Piston RINGS eie toco eade aa Pe pda reae rp e RS 3 Piston he elas Ss ed 3 ed a P 3 ON 4 Coolant Thermostat e cii Peer 4 n2 Fee Lotus Service Notes Section TDL GENERAL Type designation std 1115 Configuration amp no of cylinders Capacity Bore Stroke Valve actuation std 1115 Compression ratio Firing order Spark plugs Spark plug gap Maximum engine speed Fuel system std 1115 Fuel requirement Max power 88 195 EEC std 1115 Max torque 88 195 std 1115 Materia Head face maximum warpage Cylinder head height new reface limit CAMSHAF VALVE TIMIN Std Open duration Inlet valve opens
176. 0R is common with the Elise but is mounted on a lightened flywheel and is balanced in unit with it Page 50 Orr EXIGE SUPPLEMENT Sub Section Page Introduction EXIGE 2 Technical Data EXIGE TD 3 Chassis EXIGE A 5 Body EXIGE B 5 Front Suspension EXIGE C 9 Rear Suspension EXIGE D 9 Engine EXIGE E 9 Transmission EXIGE F 17 Wheels amp Tyres EXIGE G 18 Steering EXIGE H 19 Brakes EXIGE 19 Cooling EXIGE K 19 Fuel System EXIGE L 19 Electrical EXIGE M 20 Maintenance amp Lubrication EXIGE O 41 Heating amp Ventilation EXIGE P 41 Clutch EXIGE Q 41 2000 03 Page 1 Lotus Service Notes Exige XIGE INTRODUCTION The Lotus Exige made its public debut at Brands Hatch in April 2000 as a fully road going version of the car used in the Lotus Motorsport Elise race series The car is based on the standard Elise chassis and core body structure but using the 178 bhp powertrain from the 340R a sport suspension package a modified race replica body and race car alloy road wheels The specification has been optimised for drivers who require an uncompromising machine with respon sive handling higher engine output and an elevated level of driver satisfaction with a projected use to include track days The car is fully type approved for European markets with various changes from the race cars made to improve practicallity legality or user friendliness These changes include the fitment of a clear polycarbonate vented tailgate f
177. 111H0021F Refit the rack fixings using a suitable threadlocking compound and torque tighten the M8 bolts to 27 Nm and the M10 bolts to 45 Nm Steering rack Steel reinforcement channel bonded assembly M10 fixing bolt M8 fixing bolt Pop rivet Chassis crossmember Ee 1999 01 Lotus Service Notes Section XA At the lowered ride height the suspension geometry should be set as follows Subject Specification Tolerance Max difference side side Front Camber 0 3 0 1 0 22 0 2 std ride height 0 1 Front Caster 3 8 0 2 0 2 Front Toe 0 2 mm toe out overall 0 0 2 mm Rear Camber 2 0 0 2 0 2 std ride height 1 8 Rear Toe 1 2 mm toe in each side 0 0 2 0 2 In extreme cases it may be necessary to machine the top ball joint plinth in order to attain sufficient negative camber Rear Bump Steer The rear suspension toe links are designed to steer the rear wheels in incremental amounts as the car rolls with cornering forces in order to produce the required handling characteristics The general requirement is for the outside wheel to adopt a small amount of toe in as it moves towards bump with roll A shim stack is provided at the outboard end of the toe link by which the joint height in relation to the wishbone pivots may be adjusted A basic stack dimension detailed below will provide an approximately correct geometry but in order to optimise the characterist
178. 18 AWI O Z Rimstock TONS 1339 03 a Lotus Service Notes Section GF Lotus Service Notes Section GF uM M o j Note that the inset figure is the offset of the wheelrim centreline reletive to the wheel hub pai S 2 OUTSIDE mounting face A positive figure indicates that ace j face of the wheelrim centreline lies inboard of the whee wheel wheel mounting face whereas a negative fig ure means the wheelrim centreline is outboard of the mounting face Wheelrim centreline Wheel mounting face Inset positive shown Tyres Standard Fitment Type Pirelli P Zero Size front 185 55 R15 81V rear std 205 50 ZR16 87W 111S amp std option 225 45 ZR16 Pressure cold front 1 6 bar 23 Ib in rear 205 1 7 bar 24 5 Ib in 225 1 9 bar 27 5 Ib in Pirelli Zero 205 50 rear tyres There are variations in the specification of Pirelli tyres with this designation dependent on where and when they were manufactured Lotus fitment should be either i Made in Italy moulded on inside tyre wall or ii Made Great Britain moulded on inside tyre wall and with DOT date of week 35 year 1997 coded as 357 or later see below Note The new U K built tyre was introduced on production at VIN V 1700 approx b Italian and U K variations of rear tyre should not be mixed on the same axle C Italian built rear tyres are available under part number A111G6007H but will be superceded by
179. 2 Automatic timing belt tensioner Fit tensioner pillar bolt and tighten to 25 Nm K8 and K16 13 Fit new spark plugs tighten to 25 Nm 14 Fit camshaft cover and timing gears 15 K8 engines Fit HT lead brackets fit and tighten bolts to 10 Nm Cylinder head K16 Non VVC engines fitted with plug top coil ignition system refit CAUTION If crankshaft has been rotated check that timing marks on crankshaft timing gear are aligned with flange on oil pump and that tool 18G 1674 is locking flywheel 1 Check cylinder head bolts in oil rail See Cylinder head bolt inspection Renew bolts as necessary 2 Check that 2 locating ring dowels are fitted in cylinder block CAUTION The type of ring dowel fitted must be maintained A nylon ring dowel must not be used in place of a steel ring dowel 3 Oil cylinder head bolts under head and threads 4 Remove cylinder liner retainer clamps 18G 1736 CAUTION Do not rotate crankshaft until A cylinder head bolts are fitted 5 Fit new cylinder head gasket DRY with identification markings facing upwards on to cylinder block CAUTION Take care not to damage A sealing faces of gasket 6 Using assistance fit cylinder head on to cylinder block carefully locating ring dowels 7 Carefully enter cylinder head bolts in their originat fitted locations NOT DROP Lightly tighten bolts 8 Temporarily fit timing gears to camshafts fit but do not fully tighten bolt
180. 20 REAR RACELIGHT CONVERSION KIT A340M0042K 151390 The racelight conversion kit provides for the Centre High Mounted Stop Lamp CHMSL to be used for both a brake lamp and also a racelight activated with ignition 1 Disconnect and remove the CHMSL from the topshell and cut the lower ve feed copper track in two places as shown to separate the function of the two outermost bulbs from the inner pair 2 Replace the two outermost bulbs with 3W items 3 Solder the ends of the two green cables on the new harness to the outer bulb ve tracks 4 Refit CHMSL to topshell connect conversion harness to lamp and secure to topshell and plug in to main harness 4 way connector 5 Fit bridging link into main harness sidelamp switch connector Lamp connector plug Plug into main harness 2 2277222227272722222227 LLL LLL 92 A Solder bare ends of cables Cut copper track on conversion harness 2000 02 Page 43 Lotus Service Notes Section XA 1 TONNEAU COVER RHD A240V6000S LHD A340V6022 This tonneau cover is manufactured from an Acrylic material with a polyurethane coating on the inside and not from Haartz material as stated in some sales literature Stowage it is important that the tonneau cover is not kept in the storage bag for long periods when wet as this will affect both the aesthetics and the polyurethane coating Rear Screen If the car is for track use the rear screen
181. 3 E Lotus Service Notes Section EMN paired with 4 and 2 with 3 the spark in the cylinder on the exhaust stroke being wasted The twin coil pack is mounted on the cylinder block as for standard engines On VVC engines the variable valve contro mechanism is also controlled by the ECM Two solenoid valves attached to the hydraulic control unit on the inlet camshaft mechanism are used to distribute oil pres sure either side of a piston in order to alter the amount of inlet cam cyclical speed variation and corresponding valve timing The ECM is calibrated to recognise sensor readings which are outside of the acceptable range and if such a signal is received from the coolant sensor inlet air temperature sensor or MAP sensor it will substitute a default value to enable the engine to continue to run in a back up or get you home mode As a vehicle security measure the engine management ECM incorporates an immobilisation feature whereby a coded signal must be received from the security 5AS module before the starter and ignition circuits become active For security details see electical section MN or the Lotus Check instruction booklet SCANNER In order to provide for communication with the engine management system electronic control module a hand held electronic scanner tool Lotus Check part number T000T1346 may be plugged into a special 16 terminal harness connector socket known as a Data Link Connector DLC
182. 5 45 to 5 50 mm 5 95 to 6 05 mm H 2 0 mm radius J 0 75 to 1 25 K 45 K16 Non VVC engines not triple angle valve seats See illustration BRM 1102A Inlet 22 98 to 23 13 mm B 25 7310 25 98 mm C 29 560 to 29 573 mm D 38 E 29 475 to 29 500 mm F 5 95 to 6 00 mm G 6 53 to 6 69 mm H 2 0 mm radius 4 0 750 1 25 mm 45 Exhaust 19 58 to 19 73 mm B 21 60 to 21 90 mm C 25 960 to 25 973 mm D 30 E 25 888 to 25 913 mm F 5 45 to 5 50 mm 5 75 t0 6 41 mm H 2 0 mm radius J 0 75 to 1 25 mm 45 K16 VVC engines not triple angle valve seats See illustration BRM 1102A Inlet 27 38 to 27 62 mm B 29 40 to 29 80 mm C 32 56 to 32 57 mm D 18 to 20 E 32 475 to 32 500 mm 5 95 to 6 00 mm G 6 46 to 6 62 mm H 7 00 mm radius J 0 74 to 1 25 mm K 44 to 46 Exhaust 23 68 to 23 93 mm B 24 80 to 25 20 mm C 28 99 to 29 00 mm D 11 to 13 E 28 88 to 28 91 mm 5 45 to 5 50 mm G 6 00 to 6 16 mm H 6 0 mm radius J 0 75 to 1 25 mm K 44 to 46 54 OVERHAUL K16 Non VVC engines fitted with triple angle valve seats See illustration M12 5536 I M12 5536 Inlet 15 B x 45 60 D z 0 4 mm radius E 29 560 to 29 573 mm F 2 1 0 to 1 4 mm G 26 43 mm H x 29 475 to 29 500 mm 4 5 95 to 6 00 mm K 6 16 to 6 32 mm Exhaust Ars 15 45 C 60
183. 6 mpg 174 g km 2000 02 Page 5 Lotus Service Notes Section AF CHASSIS SECTION AF M111 Sub Section Page General Description AF 1 3 Chassis Straightness Check AF 2 4 Rear Subframe amp Longerons AF 3 5 2000 02 Page 1 Section AF E Lotus Service Notes Aeg Xue jong eureJjqns 4884 jlesapis uonsnaxe IS IN 100g NE CS Lk a L b i uo4eBuo deay dooy uoisni3xe eungonyjs use1o 001 zeas emnos ajyisodwo5 n d Page 2 Lotus Service Notes Section AF Lotus Service Notes Section AF 1 GENERAL DESCRIPTION The chassis frame of the Lotus type M111 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 crossmember bolting to the rear of the engine bay to provide rear suspension mountings and rear body support and a tubular steel roll over bar bolted to the top of the chassis structure for additional occupant protection The cabin rear bulkhead body sills inc and B posts front energy absorbing crash structure and scuttle windscreen mounting frame are all con structed from glass fibre composi
184. 7 a ain g D Oum N t H eu H H t y lt 5 RER St ga S5 p 2 z H 12 Ya m ert az Lm 5 55 E SPEED Z ite ut i bk us SENSOR EUG Pe e a 5 8 Dt Ed ar gt amp 5 z o H lt zy nn I a a H TEMP JAGE 4 ai TRANSCUCER THC zi zb oc TO FUEL PUNP SEE SHEET 2 d a m m B o x a S To T ENGINE ENGINE M M e LA usto JL E s re Lotus Service Notes Section MN WINDSCREEN WIPERS BATTERY FUSEBOX IGNITION START DROP OUT gt IGNITION UNFUSE D IGNITION FUSED SE WIPER SWITCH WIPER MOTOR INTERMII TANT WIPE MODULE gt lt o a a gt is SHEET I Lotus Service Notes Section MN INTERIOR FAN BATTERY FUSEBOX GNITION START IGNITION UNFUSED d IGNITION FUSED gt lt FAN SPEED SWITCH RESISTOR BLOCK INTERIOR SHEET 12 EG Lotus Service Notes Section MN RADIO amp CIGAR LIGHTER FUSEBOX FUSEBOX See ee ae BATTERY IGNITION START DROP OUT E IGNITION UNFUSED IGNITION FUSED
185. 773 98 onwards Manufacturer identifier Code Assembly Plant H Hethel Vehicle Type B Shah 111 Elise Engine Type Model Year Chassis Body Restraint Serial A Active belts Number G 1 8 K16 W 1998 C RHD J 1 8 VVC X 1999 D LHD K Sport 160 Y 2000 E Race 1 2001 2002 F SVA RHD For certain service operations it may by necessary to remove the engine bay undertray and or diffuser panel The panels are retained by Four M8 button head fixings needing a 5mm hexagonal key Fourteen M5 crosshead screws Diffuser to Undertray rear clamshell to sill fixings fixing Diffuser panel Undertray to park cable Engine bay undertray abutment Diffuser to subframe fixing Undertray to diffuser fixing 2000 Page 3 6 Lotus Service Notes Introduction Care must be taken when using lifting jack or hoist only to position the device in 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 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 wheel
186. 79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M94 M95 M96 M97 M98 M99 NO1 COMMENCING ENGINE NUMBERS NOTE The following modifications have been introduced at the following engine numbers Engines fitted to Rover 25 45 and 75 models incorporate these modifications from commencement of production K16 Non VVC engines fitted with automatic timing belt tensioner 14K4FK76 646038 14K4FK76 885300 14K4FK77 655218 14K4FK77 885300 14K4FL30 153524 14K4FL30 885300 14K4FL31 154156 14K4FL31 885300 16K4FK79 654924 16K4FK79 885300 16 4 80 655078 16K4FK80 885300 16K4FL32 153217 16K4FL33 152709 16K4FL34 149204 16K4FL35 145785 18K4FJ31 153993 18 4 32 147263 18K4FJ78 151555 18K4FJ79 153785 18K4FJ89 146503 18K4FJ90 141815 18K4FL66 148135 18K4FL67 665464 18K4KL36 118709 18K4KL37 102149 INTRODUCTION K16 Non VVC engines fitted with modified camshafts and cylinder heads 14K4FK76 872191 14K4FK77 872382 14K4FL30 114520 14K4FL30 872041 14K4FL31 104073 16K4FK79 872751 16K4FK80 872285 16K4FL32 114135 16K4FL33 112837 16K4FL34 110965 16K4FL35 110541 18K4FJ31 112397 18K4FJ32 111281 18K4FJ78 115630 18K4FJ79 112575 18K4FL66 674985 18K4FL67 110704 18K4KJ89 110206 18K4KJ90 683004 18K4KL36 703592 18K4KL37 703768 Cylinder heads fitted with triple angle valve seats 14K4FK76 853697 14K4FK77 853547 14K4FL30 684272 14K4FL31 682772 16K4FK79 853606 16K4FK80 853676
187. 9 Inspect operation of all lights inspect operation of all electrical equipment SS inspect operation amp condition of seat belt harnesses Top up screenwash reservoir X Renew alarm transmitter batteries check with customer p spl Road Test Performance Engine performance Tailpipe CO oeil Clutch operation 2 2 2 Gearbox operation E T Brake performance Steering performance Driveline amp suspension noise vibration Wheel balance teer General 6 C Additional work required Work completed Dy Dealer stamp Recommended Service Times After Sales Service 1 8 hr A Service 2 8 hr B Service 3 2 hr C Service 6 7 hr Add 0 5 hr to all if undershield fitted i service table sn_340R_t2 emf Page 49 EGO 340R P HEATING A rudimentary heater is provided in the form a hot air duct linking a portion of the engine radiator outlet airflow to the vents at the front of the footwells Note that the windscreen is electrically heated see section M 340R Q CLUTCH The clutch used on the 34
188. ATA TORQUE amp TOOLS 3 ENGINE Piston rings New ring to groove clearance K8 and K16 1 1 and 1 4 Top compression ring 0 04 to 0 08 mm 2nd compression ring 0 03 to 0 062 mm Oil control 0 044 to 0 055 mm K16 1 6 and 1 8 Top compression ring 0 040 to 0 072 mm 2nd compression ring 0 030 to 0 062 mm Oil control 0 010 to 0 180 mm Ring fitted gap 20 mm from top of bore K8 and K16 1 1 and 1 4 Top compression ring 0 17 to 0 37 mm 2nd compression ring 0 37 to 0 57 mm Oil control 0 15 to 0 40 mm K16 1 6 and 1 8 Top compression ring 0 20 to 0 35 mm 2nd compression ring 0 28 to 0 48 mm Oil control 0 15 to 0 40 mm Piston diameter K8 and K16 1 1 and 1 4 Grade A o un Tat 74 940 to 74 955 mm GradeB ciues y Ly adu E gene 74 956 to 74 970 mm Clearance bore 0 015 to 0 045 mm Maximum ovality 0 3 mm K16 1 6 and 1 8 Grade A 79 975 to 79 990 mm Grade s 79 991 to 80 005 mm Clearance bore 0 01 to 0 04 mm Maximu
189. AUTION If crankshaft has been rotated check that timing mark on crankshaft timing gear is aligned with fiange on oil pump and that tool 18G 1571 is locking flywheel 1 Check cylinder head bolts in oil rail See Cylinder head bolt inspection Renew bolts as necessary 2 Check that 2 locating dowels are fitted in cylinder block 3 Oil cylinder head bolts under heads and threads of bolts 4 Remove cylinder liner retainer clamps 18G 1736 CAUTION Do not rotate crankshaft until A cylinder head bolts are fitted Fit new cylinder head gasket ORY with identification marks facing upwards on to cylinder block CAUTION Take care not to damage N sealing faces of gasket 6 Using assistance fit cylinder head on to cylinder block carefully locating ring dowels 7 Carefully enter cylinder head bolts in their original fitted locations NOT DROP Lightly tighten bolts 72 OVERHAUL ENGINE eese o 9 H Ze EXC lt pec Z 12M2037 8 Tighten cylinder head bolts progressively in sequence shown to 20 Nm Use a felt tip pen and mark position of radial mark on each bolt head Tighten bolts in sequence shown through 180 Tighten all bolts in sequence shown a further 180 and align marks CAUTION If any bolt is overtightened back off 90 and re align 9 Fit camshaft cover and timing gears 10 Fit new spark plugs tighten to 25 Nm Camshaft cover and timing gear K8 engines r
190. At the rear of the tunnel the harness passes through the fuel tank bay to emerge at the left hand front of the engine bay from where it runs to the LH side panel to feed the engine and rear harnesses then across the rear of the chassis to the fog and reversing lamps An additional branch is routed across the top of the cabin rear bulkhead to feed the two speakers A front harness is fixed to the clamshell to feed the headlamps turn and repeater lamps and plugs into the main harness at the RH side Similarly a rear harness is fitted to the rear clamshell to supply the rear lamps with a connector on the LH side panel Front harness connector Horn Main fusebox Optional driving 24 lamps j 2 LS Blower motor connector Radiator fan connector Page 23 E Lotus Service Notes Section MN Main harness along dash LHD shown Instrument pack Lucas 5AS module Push switches Hazard amp wash wipe module connector Interior lamp Column switch connectors Immobilier touch key socket Of Cobra Alarm Harness Gs RHD shown Lucas 5AS module connectors Alarm controller Connector to siren unit Main harness connector Buzzer unit m18 Page 24 C Lotus Service Notes Section MN Main harness into engine ba Engine management earth point Harness secured to roll bar brace Harness out of Engine fuel tank bay earth Chassis Wheel speed lead
191. Bracket fixing bolts Wiper motor assembly 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 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 21 Section MN RHD Shown LHD symmetrically opposite Wiper linkage in full travel position 6 Re assemble in the reverse order to removal torque tightening the bracket bolts to 20 Nm MN 8 FITMENT OF DRIVING LAMPS The optional driving lamps mounted in the air intake aperture provide additional lighting on main beam operating in conjunction with the main headlamps All cars are built with a wiring harness which accommo dates the driving lamps which may therefore be retro fitted on any car if the air intake grille is also replaced Parts Required Description Part Number Qty Driving Lamp A111M6008F 2 Air intake Grille 111 0059 1 Mounting Plate LH A111B0051F 1 Mounting Plate RH A111B0050F 1 Pulsert M8 mounting plate fixing A075W6155F 6 Plastic Screw M8 x 25 plate fixing A082W6530F 6 Washer plate fixing A111W4156F 6 Plastic Scr
192. C Notes ON UN D ON B gt N FUSE 10 7 5 HORN RELAY Pa pthc Se 1 o 1 1 1 1 P N SPLICE t FUSE A8 A TT gt HORN PUSH ter d B PY sheet 14 Page 42 SEE SHEET 3 SPLICE FUSE 1 3amp FUSE AS 3amp 1 STOP LIGHT SWITCH BULK 24 iz 5 GP ZN SEE SHEET 8 BULK 44 RHLHC 1 LHLHC 1 CHMSL 1 RH LHC 2 LHLHC 2 CHMSL 2 sheet 15 REAR FOG RELAY under dash RY SPLICE G O BULK 48 REVERSE LAMP SWITCH 5 RHC 6 FOGHC 1 FOG HC 3 REVERSE LAMP FOG LAMP Page 43 E Lotus Service Notes 340R Page 44 EG Lotus Service Notes 340R RS Lotus Service Notes 340R Lubricants are as for standard Elise The maintenance schedule is basically the same except the distance interval is reduced from 9 000 miles 15 000 km to 6 000 miles 10 000 km to reflect the likely harder use of the vehicle For normal road use the engine oil and filter should be changed in accordance with this schedule but for cars used on race circuits oil and filter should be changed every 3 000 miles 5 000 km For seriously raced cars oil and filter should be changed every 2 meetings The engine is factory filled with Castro GTX 15W 50 to be used for running in until the After Sales Service At this service it is recommended to use a fully synthetic oil for
193. CES Clean inlet and exhaust manifold joint faces 2 De carbonise combustion areas of cylinder head and valves as necessary 3 Blow out oilways and waterways ensure oil feed to camshaft carrier is clear NOTE Cylinder heads fitted to later engines have a 4 5 mm diameter oil drain hole drilled through the head from the camshaft oil seal recess ensure drilling is clear 4 K8 engine Check fuel pump blanking plate if fitted for signs of oil leakage Replace gasket if necessary tighten blanking plate nuts to 25 Nm OvERHAUL 49 ENGINE Cylinder head inspection 1 Check cylinder head for damage pay particular attention to gasket face of cylinder head 2 Check cylinder head face for warping across centre and from corner to comer Cylinder head Maximum warp 0 05 mm 3 Check cylinder head height New 118 95 to 119 05 mm Cylinder heads may be refaced Reface limit 0 20 mm CAUTION Cylinder heads fitted to K16 engines with automatic timing belt tensioners are not interchangeable with those fitted to engines with manual tensioners 50 OVERHAUL Valve springs inspection 1 Check condition of valve springs NOTE Valve springs are either colour x coded or plain K8 Yellow red K16 Non VVC engines Plain K16 VVC engines Blue K8 Free length 46 2 mm Fitted length 37 0 mm Load valve closed 255 12N Load valve open 535 20 K16 Non VVC engi
194. CK 2 CL o B SHEET 19 Lotus Service Notes Section SOLENOID VALVE CONTROL CARS BATTERY IGNITION ISTART DROP OUT IGNITION UNFUSED ps SPLICE SPLICE IGNITION FUSED SOLENOID VALVE Gi FOOTWELL FLAP CONTROL SWITCH 8 SOLENOID SOLENO 50 SCREEN FLAP ID Ta Le uA SHEET 20 Lotus Service Notes Section MN AC REQUEST amp CONTROL NON HEATER VERSION BATTERY gt IGNITION START OROP OUT gt FUSEBOX IGNITION UNFUSED IGNITION FUSED gt ACU CONTROL MOOULE gt FAN SPEED SWITCH SEE SHEET 19 2 E AC CLUTCH RELAY ACU TEMP CONTROL ACU THERMISTOR E ON OFF SWITCH GK B m AC COMPRESSOR CLUTCH EHC Lt lt SIDELAMPS 17 a D gt Gk AC REQUEST RELAY BR IDUING LINK AC CONTROL p 8 ES L E C U MEMS 1 9 AC RAD CAONTROL P 35 Ee 5 B SHEET 22 Lotus Service Notes Section OG MAINTENANCE amp LUBRICATION SECTION OG M111 ELISE Page Recommended Lubricants 2 Maintenance Schedule 4 Pre Delivery Inspection 7 1998 N3 TAUGA Lotus Service Notes Section RECOMMENDED LUBRICANT
195. ENGINES FITTED WITH MANUAL TIMING BELT TENSIONER M124933 1 Upper front cover timing belt 2 Screw M6 upper cover 3 Seal upper cover 4 Bolt M6 x 90 upper and lower cover 5 Lower cover timing belt 6 Seal lower cover 7 Screw M6 lower cover 8 Screw M6 x 16 lower cover 9 Crankshaft pulley 10 Special washer pulley bolt 11 Crankshaft pulley bolt 12 Camshaft timing belt 13 Camshaft timing gears 14 Camshaft gear bolt 15 Plain washer 16 Tensioner pulley and backplate 17 Allen screw pulley 18 Tensioner spring 19 Sleeve spring 20 Pillar bolt 21 Flange head screw tensioner backplate 22 Crankshaft timing gear 23 Rear cover timing belt 24 Screw rear cover to coolant pump 25 Screw rear cover DESCRIPTION AND OPERATION 13 ENGINE TIMING BELT COMPONENTS K16 NON VVC ENGINES FITTED WITH AUTOMATIC TIMING BELT TENSIONER M124970 1 Upper front cover timing belt 13 Camshaft timing gears 2 Screw M6 upper cover 14 Camshaft gear bolt 3 Seal upper cover 15 Plain washer 4 Bolt M6 x 90 upper and lower covers 16 Bolt tensioner 5 Lower cover timing belt 17 Tensioner 6 Seal lower cover 18 index wire 7 Screw M6 lower cover 19 Pointer 8 Screw M6 x 16 lower cover 20 Pillar boit 9 Crankshatt pulley 21 Crankshaft timing gear 10 Special washer pulley bolt 22 Screw rear cover 11 Crankshaft pulley bolt 23 Screw rear cover to coolant
196. Eege EK 9 Selector shafts eee oro eo ce erre etes e secco ceu sis de de s yep ae teneo ve sa eant ca guid dd 11 Sth Reverse Selector with reverse brake 22222 2 2 4 11 InterlocK Assembly oret nae oc Eros ropa ee aae Dee eaa eed 12 Differential Assembly 20 nennen 12 INSPECTING COMPONENTS 13 Input and Output Shaft Assemblies 2 2 4 2 13 Reverse Idler Shaft and Gear 2 2 22 2 2 2 2 2 14 Synchro Assemblies arae ue vea os eno eet r an a Sen 14 Selector Shafts and Forks 2 2 42142 4 15 Interlock Assembly 2 2 retorno tno tee ene ine 16 Differential Assembly 17 Differential Housing EE 17 COMPONENT ASSEMBLING 2 19 Differential o terree aee tede conet too 19 Synchro Assemblies 22 4 2 22 2422 02 17 70 1 00 19 Selector Shafts 20 Reverse Idler Gear and Shaft 2 2 2 2 4 4 1 20 Input Shaft DO EP ga 20 Output Shaft SEENEN
197. F Description Application Notes One component moisture curing adhesive providing high strength permanently elastic bonds between various substrates Supplied in 300 aluminium cartridge 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 If the adhesive has to be touched or manipulated for any reason use only wetted fingers BETAMATE E2400 A082B8415V Description Application Notes Page 8 Two component chemically curing adhesive providing high strength permanently elastic bonds between various substrates Supplied 220 and 450 aluminium cartridges 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 If the adhesive has to be touched or manipulated for any reason use only wetted fingers Lotus Service Notes Section BM Air gun Betaseal cartridge 6 REPLACEMENT OF BONDED ON PANELS GENERAL Bonded body panels are
198. Guide Depth Gauge K8 Engines Valve Stem Oil Seal Remover Replacer Crankshaft Front Oil Seal Replacer K16 VVC Housing Oil Seal Replacer Elysees Locking Tool Flywheel Fitted With Reluctor ing Cylinder Liner Retainer Clamps Sump Alignment Pins 2 off Camshaft Front And Rear Oil Seal Replacer Camshaft Clamp K16 VVC Engines Timing Plate Front Inlet Camshaft K16 VVC Engines Timing Plate Rear Inlet Camshaft K16 VVC Engines Camshaft Oil Seal Protection Sleeve Valve Guide Reamer All K16 Engines Valve Guide Reamer K8 Engines Valve Seat Cutter Pilot 60 Valve Seat Cutter 15 Valve Seat Cutter 45 Valve Seat Cutter Camshaft Holding Tool DATA TORQUE amp TOOLS 7 Lotus Service Notes Section EMN ENGINE MANAGEMENT amp FUEL INJECTION SECTION EMN M111 ELISE Section Page Introduction amp Component Location EMN 1 3 Lotus Check Scanner Tool EMN 2 4 Throttle Cable Adjustment EMN 3 7 Electronic Control Module ECM EMN 4 7 Relay Module EMN 5 8 Manifold Absolute Pressure MAP Sensor EMN 6 9 Crankshaft Position Sensor EMN 7 10 Engine Coolant Temperature ECT Sensor EMN 8 11 Intake Air Temperature IAT Sensor EMN 9 12 Throttle Position TP Sensor EMN 10 13 Idle Air Control IAC Valve EMN 11 14 Oxygen O2 Sensor EMN 12 1 5 Camshaft Position Sensor VVC only EMN 13 16 VVC Mechanism Control Solenoids VVC only EMN 14 17 Oil Temperature Sensor VVC only EMN 15 18 Fuel System EMN 16 19 Ignit
199. ICES HAZARD LAMPS 7 5A HORN 10A ALARM amp INTERIOR LAMP 25A COOLING FAN FUSEBOX B RATING APPLICATION 1231 20A RADIO 14 zCA LIGHTER 15 __5 SIDELAMPS LH 16 SA SIOELAMPS RH FUEL PUMP FUSE RATING APPLICATION 71 17 194 FUEL PUMP MAXI FUSES L 1 1 ee NO RATING APPLICATION 50 IGNITION SWITCH 02 50 HE ADL AMPS 03 30A ENGINE SYSTEM SHEET 16 Lotus Service Notes Section MN R MN 12 COBRA 6422 VEHICLE SECURITY ALARM U K option The optional upgraded vehicle alarm system on U K market cars was updated from a Cobra 6019HF to a Cobra 6422 based system from the following change point VIN W 1947 October 97 plus W 1938 The 6422 system meets Thatcham Category One standards pertinent to the U K insurance industry and operates in much the same way as the previous 6019HF system which also qualified for category one but significant differences include New ergonomic transmitter key Deletion of override switch on siren housing Facility to programme new transmitter keys Special note should be taken of the potential for inadvertent transmitter code wiping possible when using the touch key which is only required in case of transmi
200. IGNITION START DROP OUT gt IGNITION UNFUSEO gt 36 3 1 5 m a 87 5 a 10 5 3 i D a 2 2 5 a Vru 5 22 _ gt gt gt 2 LH LAMPS 6 a a a a FHC FHC TO SIDELAMP SWITCH SEE SHEET 9 HEADLAMP SWITCH TO SIOELAMP SWITCH SEE SHEET 9 INSTRUMENT PACK MAIN BEAM WARNING TO FOG LAMP FUSE SEE SHEET 9 IGNITION FUSED I gt 5 8 Lotus Service Notes SIDELAMPS amp FOG LAMP Section MN BATTERY IGNITION START DROP OUT gt IGNITION UNFUSE 0 IGNITSON FUSED SWITCH SIDELAMP SWITCH TO RADIO SEE SHEET LH LAMPS REAR FOG LAM SWITCH TO HAZARD SWITCH SEE SHEET 7 Ea 2 INSTRUMENT PACK E SHEET 10 NE CIGAR LIGHTER SHEET 19 RH LAMPS gt Lotus Service Notes Section MN FUSEBOX BATTERY Res gt IGNITION START DROP OUT gt IGNITION UNFUSEDI P IGNITION FUSED B 4 SEAT BELT a RN WARNING Al BUZZER INSTRUMENT PACK Hu E a 3 o a HN 1 2 Ent Jm irme
201. ING APPLICATION 01 SCA 10417104 SACH 2921 504 EALLAMPS C EQUIPED VEHICLES ONLY EQUIPED VEHICLES EQU PED VEHICLES EQLiPED VEHICLES ONLY ONL Y ONLY SHEET 16 Lotus Service Notes Section MN HOT SOAK PUMP A C CARS FUSEBOX SPLICE C BATTERY IGNITION ISTART OROP OUTI IGNITION UNFUSED SPLICE IGNITION FUSE 01 HOT SOAK SWITCH 20 SOAK PUMP TSPLice TSPLice SHEET 17 Lotus Service Notes Section MN COOLING FAN RELAY 2 A C CARS FUSEBOX BATTERY IGNITION START DROP OUT gt IGNITION UNFUSED gt E CU MEMS 13 HH G BN 25A o as BE 3 gt x a lt gt les 1 3 Fog S EHC Vo i 1 H DO 1 5 TOR zo a 5 EE 1 IGNITION FUSED gt 2 1 STS IRE AR gt SHEET 18 Lotus Service Notes section MN INTERIOR FAN A C CARS FUSEBOX BATTERY FUSEBOX IGNITION START DROP OUT gt IGNITION UNFUSE 01 0 0 lt Vo Vn SAX Si FAN SPEED SWITCH EU gt gt A c ON OFF SWITCH Q AND A C CLUTCH RELAY FAST FAN SPEED RELAY 5 Uv 2 87 e G QOQOO 85 RESISTOR a BLO
202. ION 1 INTRODUCTION SPECIFICATION Rover are constantly seeking to improve the specification design and production of their vehicles and alterations take place accordingly While every effort has been made to ensure the accuracy of this Manual it should not be regarded as an infallible guide to current specifications of any particular vehicle This Manual does not constitute an offer for sale of any particular vehicle Rover Dealers are not agents of Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation ENGINE NUMBER LOCATION 12M1762 The engine number will be found stamped either on the LH side of the bearing ladder or cast on the rear LH side of the cylinder block 2 INTRODUCTION ENGINE SERIAL NUMBER PREFIXES Engines covered by this overhaul manual have the following prefixes in the engine serial number H63 H64 H67 H71 H72 H75 H76 H77 H78 J31 J32 J78 J79 J89 J90 K38 K39 K40 K41 K43 K44 K45 K51 K53 K61 K63 K67 K68 K74 K76 K77 K78 K79 K80 K88 K89 06 107 108 LOS L10 L24 L25 L28 130 131 L32 L33 L34 L35 L36 L37 L44 L45 L46 L47 L48 149 L50 L51 164 L67 168 169 L82 L97 L98 L99 K79 K80 K88 K89 M01 M21 M22 M23 M26 M27 M28 M29 M30 M31 M36 M37 M38 M39 M41 M42 M47 M48 M49 M50 M51 M52 M53 M54 M55 M56 M62 M64 M65 M67 M68 M70 M71 M72 M73 M75 M76 M
203. Inlet valve closes Exhaust valve opens Exhaust valve closes Valve overlap Valve lift inlet exhaust 111S Open duration inlet variable exhaust Inlet valve opens Inlet valve closes Exhaust valve opens Exhaust valve closes Valve overlap variable Valve lift inlet exhaust VALV Angle of valve seats and faces Stem diameter inlet exhaust K16 18K4F K16 18K4K in line 4 1796 cm 70 71 in 80 00 mm 3 150 in 89 30 mm 3 516 in Belt driven twin overhead camshafts with hydraulic tappets As std with variable valve control VVC on inlet camshaft 10 5 1 1 3 4 2 RC8 PYP or CSP 9652 0 9 0 1 mm 0 035 in 7000 rpm Multi point grouped fuel injection with MEMS 1 9 engine management Sequential fuel injection with MEMS 2J engine management Unleaded 95 RON minimum 88 kW 118 bhp 5 500 rpm 107 kW 143 bhp 7 000 rpm 165 Nm 122 Ibf ft 3 000 rpm 174 Nm 128 Ibf ft 4 500 rpm Aluminium alloy 0 05 mm 118 95 to 119 05 mm 0 20 mm 244 at crankshaft 12 BTDC 52 ABDC 52 BBDC 12 ATDC 24 8 8 mm 8 8 mm 220 to 295 252 0 BTDC at minimum period 40 ABDC at minimum period 51 BBDC 21 ATDC 21 to 58 9 5 9 2 45 5 952 5 967 5 947 5 962 2 Stem clearance in guide inlet new service limit exhaust service limit Valve c
204. K16 Non VVC engines remove K8 Ce TERME TE PAY AL rene oen 12M0578 1 Using sequence shown progressively slacken 22 bolts securing camshaft carrier to cylinder head until valve spring pressure is released remove bolts 1291994 2 Remove camshaft carrier i NOTE Dowel located 3 4 5 Remove camshaft Remove and discard camshaft oil seals Using a stick magnet remove 8 tappets from cylinder head Retain tappets in their fitted order and invert to prevent oil loss 36 OVERHAUL ENGINE 9 K16 I I AERE A YT M124973 10 m 10 CAUTION Camshafts fitted to later 9 engines incorporate reluctor ring these camshafts are not interchangeable with those fitted to early engines Commencing engine numbers for the modified camshafts are listed in Information NOTE Camshafts incorporating a reluctor SR ring illustrated 6 Remove 2 bolts securing blanking plate to rear of camshaft remove plate NOTE On engines fitted with plug coil ignition blanking plates are fitted for both inlet and exhaust camshafts 7 Using sequence shown progressively slacken 26 bolts until valve spring pressure is released Remove bolts 8 Remove camshaft carrier e 9 Suitably identify each camshaft to its fitted position remove camshafts 10 Remove and discard oil seals from camshafts 11 Using a stick magnet remove 16 tappets from
205. KPa during idle Very high values may indicate a faulty sensor or a blocked or leaking connecting hose Moderately raised values indicate a possible engine fault On WC engined cars the MAP sensor is mounted directly onto the front end of the intake plenum and by avoiding the damping effect of a connecting hose is able to respond more quickly to changes in plenum pressure When replacing the sensor renew the O ring and tighten the two fixing screws to 9 Nm MAP sensor line liquid trap MAP sensor 2000 7 01 Page E Lotus Service Notes Section EMN The signals provided by the crankshaft position sensor enable the ECM to determine engine speed crankshaft position The inductive type sensor is mounted by a single fixing into a flange at the right hand rear of the cylinder block where it protrudes towards reluctor ring machined into the front face of the flywheel Single fixing screw Crankshaft position sensor The reluctor ring has raised poles at 10 intervals which pass within an air gap of the sensor tip and provide a voltage pulsing reference signal used for engine speed calculation Four missing poles enable the ECM to determine the crankshaft position in order to correctly time the ignition and fuel injection sequence Missing poles are positioned as follows relative to no 1 cylinder Standard VVC TDC 110 BTDC 50 BTDC 150 BTDC 180 BTDC 300 BTDC 240 BTDC 330 BTDC Note that on
206. Large button Key tell tale Small button oh102 3 Arming the Alarm Remove the ignition Key close and lock both doors and check that the engine lid and front bonnet are shut The roof may be either raised or stowed Press once the larger of the two buttons on the transmitter key This command will be acknowledged by Two flashes of the hazard warning lamps Flashing of the alarm tell tale in the instrument pod Check that these indications occur If not press the button a second time as the first press have Switched off the passive immobilisation see later 31 Lotus Service Notes Section MN Note that if the system is armed when a door engine lid or front bonnet is not fully closed a buzzer will sound continuously until the opening is secured If still open after 40 seconds the siren will sound After arming the system a period of at least 40 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 Opening a door engine lid or front bonnet S Movement detected within the cockpit Energising the ignition circuit hot wiring When triggered the electronic siren will sound and the hazard warning lamps will flash for a period of approximately 30 seconds before closing down and resetting ready for any further triggering input If the engine lid or front bonnet are left open the alarm will repeat after
207. Make sure the lock plate and AN retaining spring are correctly located on 5ihireverse selector filted with reverse brake 3 Slide 1st 2nd gear selector fork on to 1st 2nd selector shaft 4 Locate 1st 2nd selector shaft in 5th reverse gear selector and 5th gear selector fork 5 Locate lug on shift arm guide in gearshift holder 6 Position gearshift holder to interlock fit shaft Reverse Idler Gear and Shaft 1 Fit a new thrust washer 2 Smear needle bearing rollers with petroleum jelly and fit in gear 3 Fit reverse idler gear to shaft NOTE Boss on gear mus face lowards thrusi washer cS OE nl 20 OVERHAUL Input Shaft NOTE Smear needie bearing rollers with petroleum jelly prior to assembly Fit needle bearing rollers in third gear Fit 3rd gear on shaft Fit 3rd 4th synchro assembly Fit needle bearing rollers in 4th gear position gear on collar and fit assembly on shaft 5 Fit needle bearing rollers in 5th gear position gear on collar eh NOTE Boss on Sth gear must face away from 4th gear 6 Fit 5th synchro assembly NOTE Machined groove in synchro hub must face towards 5th gear and large chamfer on synchro sleeve must face away from 5th gear 7 Fit a new input shaft bearing 10 where this occurs always fit a slightiy thinner pack to avoid pre loading bearings 11 12 13 MANUAL GEARBOX 0 0 Select circlip s from sizes availa
208. Matching Not applicable on Cobra cars Each transmitter key has a unique coded signal which the 5AS unit must be programmed to recognise Up to four transmitters may be matched with a module but all must be available and matched in the course of one operation Select Set Up User and after entering the password and VIN see above select Transmitter and follow the displayed instructions User Password Changing or Recharging Select Set Up Supervisor and enter the supervisor password Follow instructions displayed MN 3 SWITCHES amp INSTRUMENTS DRIVER S INFORMATION Ignition Starter Switch Steering Lock The switch lock is located on the right hand side of the steering column l Insert the key into the slot and turn clockwise to position to unlock the steering column If the key is reluctant to turn wriggle the steering wheel to ease the load on the steering lock Turn to position Il to switch on the ignition and operate auxiliary equipment Turn further clockwise to Ill against spring pressure to operate the starter motor As soon as the engine starts allow the key to return to position Il To stop the engine turn the key back to I Column unlocked Key insert remove Ignition auxiliaries Engine crank Page 9 S Lotus Service Notes Section MN Passive Immobilisation the ignition has been switched off for longer than 30 seconds it is possible tha
209. N 21 ENGINE CONTENTS Page DESCRIPTION AND OPERATION CYLINDER BLOCK COMPONENTS 04 44 0 3 CYLINDER HEAD COMPONENTS K8 ENGINES 5 CYLINDER HEAD COMPONENTS K16 NON VVC ENGINES FITTED WITH DIS TRIBUTOR 22 2 eere TE 7 CYLINDER HEAD COMPONENTS K16 NON VVC ENGINES FITTED WITH PLUG TOP COIL IGNITION SYSTEM 020 eme 9 CYLINDER HEAD COMPONENTS K16 VVC ENGINES 11 TIMING BELT COMPONENTS K8 ENGINES esee 12 TIMING BELT COMPONENTS K16 NON VVC ENGINES FITTED WITH MANUAL TIMING BELT TENSIONER eee enne 13 TIMING BELT COMPONENTS K16 NON VVC ENGINES FITTED WITH AUTOMATIC TIMING BELT TENSIONER s n 14 FRONT TIMING BELT COMPONENTS 16 VVC ENGINES 15 REAR TIMING BELT COMPONENTS K16 VVC 16 OPERATION p HH 17 OVERHAUL CAMSHAFT TIMING BELT K8 ENGINES see 1 CAMSHAFT TIMING BELT K16 ENGINES 4 oM Lm Ma 15 COOLANT PUMP 5 19 THERMOS TAT EE 20 FLYWHEEL AND STARTER RING GEAR 2 2 2 21 CYLINDER HEAD 1 netter ii re t E A eu Tae Eadie 23 CYLINDER HEAD BOLTS INSPECTI
210. New harness introduced at VIN W 1941 Plus 1920 1926 1937 1938 Less 1965 2002 Component Siting 1 Switch Box Assembly Position the switch box on the car centreline or offset if plumbed in fire extin guisher system is fitted beneath the dash mark up the two pre drilled holes in the box against the dash and drill the dash to secure the box using two self tapping screws 075 50142 Route the harness alongside the main harness and through the bulkhead grommet to the front of the battery well Route harness through grommet WW Operating switch box gt 4 d Bowden cable A P clip Page 26 8 Lotus Service Notes Section XA 2 Master Switch Relay Using one existing Pulsert in the battery well mark up and drill a second fixing hole 9mm diameter and fit an M6 Pulsert AO79W6156F Secure the relay using two M6 screws with a P clip located under one of the fixings to carry the alternator dump resistor 3 Drill the topshell 13 mm diameter in the position shown to locate the Bowden pull cable Fit the cable handle and route the cable through the front compartment and plastic bulkhead cover to the operating switch housing Fit the inner cable through the hole in the switch lever and fix the outer cable adjuster in the casing Secure the cable to the dash underside with a P clip as shown Bowden cable handle Alternator dump resistor Route cable through Master panel switch relay Existing
211. ON 78 CRANKSHAFT MAIN amp BIG END BEARINGS 2 2 2422024422 24 79 PISTONS RINGS amp CYLINDER LINERS seem 92 DATA TORQUE amp TOOLS DATA EE 1 TORQUE WRENCH SETTINGS sss eee 5 SERVICE TOOLS 7 ENGINE CAMSHAFT TIMING BELT K8 ENGINES Remove 1 Slacken bottom bolt securing timing belt upper front cover NOTE Remove bottom bolt when cover is A not slotted 2 Remove 6 bolts trom timing belt upper front cover 3 Remove timing belt upper front cover and seal 12M0556 4 Rotate crankshaft clockwise to align camshaft gear timing marks with top face of cylinder head 90 CAUTION Do not use camshaft gear gear retaining boit or timing belt to rotate crankshaft 5 Check that timimg mark on crankshaft pulley is aligned with mark on timing belt tower cover 6 Position fiywheel locking tool 18G 1571 to flywheel 7 Secure with 2 bolts OVERHAUL ENGINE Refit 1 Clean timing gears coolant pump drive gear and tensioner pulley CAUTION If the sintered gears have been subjected to prolonged contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the b
212. PTION AND OPERATION ENGINE asss CYLINDER HEAD COMPONENTS 8 ENGINES CONAN SwOn Engine oil filler cap Filler cap seal ht clip mounting bracket Clip 2 ht leads Bolt bracket Camshaft cover Gasket Bolt camshaft cover Cylinder head bolt clip mounting bracket Clip 4 ht leads Bolt bracket Mounting bracket duct Camshaft carrier Bolt camshaft carrier long Bolt camshaft carrier short Locating dowel camshaft carrier Camshaft Drive pin camshaft gear Camshaft oil seal Hydraulic tappet Collets valve Valve spring cap Valve spring Valve stem oil seal Valve guide Exhaust valve Valve seat insert exhaust Inlet valve Valve seat insert inlet Cylinder head Coolant temperature sensor Coolant outlet elbow Bolt coolant outlet elbow Gasket coolant outlet elbow Spark plug Cylinder head gasket Fuel pump blanking plate if fitted Gasket Nuts blanking plate DESCRIPTION AND OPERATION 5 ENGINE 12M1761A 6 DESCRIPTION AND OPERATION CYLINDER HEAD COMPONENTS K16 VVC ENGINES FITTED WITH DISTRIBUTOR COON OO P oO MM Spark plug cover Screw 4 cover Screw retaining washer Engine oil filler cap Filler cap seal Spark plug Clip ht leads Bolt M6 camshaft cover Camshaft cover Camshaft cover gasket Camshaft carri
213. Page 15 16 17 18 19 20 Lotus Service Notes Section BM Press over each part of the windscreen frame panel joint to ensure sufficient spread of the adhesive and use clamps as necessary to retain the frame whilst the adhesive cures If necessary use a spatula to smooth out or remove any excess or extruded adhesive 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 Examine the whole of the bonding jointline for sealing integrity and if necessary apply additional adhe sive to seal any gaps Use a spatula to smooth any visual areas to a neat finish Do not disturb the frame until the adhesive has fully cured see sub section BN 5 Fit the windscreen see sub section BN 13 instrument binnacle and dash BN 12 front clamshell BN 4 doors BN 7 and other components as necessary BN 9 SILL PANELS The sill panels incorporate the A and B posts and are bonded to the chassis windscreen frame dash baffle rear bulkhead panel and capping rail The top and bottom flanges of the sill centre section are bonded into grooves in the chassis sills 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 shor
214. RELAY UNIT I RUD gt Gs zi x 3 2 gt lt i SE t 5 ALTERNATOR A H z a Os 1 x be 1 7k N ALARM LUCAS E STARTER WOH i i T J J gt ENGINE ENGINE 1 SHEET I E Lotus Service Notes Section MN FUEL PUMP amp COOLING FAN H FUSEBOX BATTERY IGNITION START OUT D IGNITION UNEUSE DI BRIDGING L NK OR IBRA IMMOBILISER 17 P INERTJA SWITCH E Suv Du an E 1 J gt gt lt 1 gt J EL U MEMS I9 9 COOL iNo FAN gt a gt B O N FEL Tada SENER 27 SEE SHEET IO I CHASSIS REAR o uu le COOLING FAN RELAY IGNITION FUSED SHEET 2 Section MN C53 Lotus Service Notes ENGINE MANAGEMENT SYSTEM BATTERY FUSEBOX gt TI IGNITION START DROP on IGNITION NEU SE 0 IGNITION IFUSED 54 Sv3n Wavy DIAGNOSTIC CONNECTOR OBOZ ul lt lt yp s Su gu ae gt
215. Remove the bayonet bulb from its holder Turn Indicator Twist the bulb hoider counterclockwise and withdraw from the lamp body Replace the bayonet fitting bulb in the holder and twist the holder back into the lamp with the TOP mark uppermost Battery Charger For easy connection of a battery management charger U K A340M6012F Europe A340M6015F a jack plug socket is provided ahead of the gear lever val Note that the body topshell must be removed to allow the battery to be withdrawn Page 27 EG Lotus Service Notes 340R Circuit Starter Alternator Ignition Fuel Pump Ignition Coil Radiator Fan ECM Control ECM Power Supply Sensors Wiper Motor Turn Indicators Hazard Lamps Heated Front Screen Instrument Controller Meta Immobiliser Meta Alarm Headlamps Sidelights Auxiliary Power Sockets Horn Rear Fog Reverse Brake Lamps GLOSSARY OF TERMS Abbreviation IMHC BULK FTHC FTU ccc AHC OP CONN FHC CHMSL HC INSTR CON FOG HC LHC HDL HC Page 28 Expansion IMmobiliser Harness Connector 48 way circular connector Fuel Tank Harness Connector Fuel Tank Unit connector Centre Console Connector Alarm Harness Connector OPtion CONNector Front Harness Connector 1 amp 2 Central High Mounted Stop Lamp Harn Conn INSTRument CONtroller harness connector FOG lamp Harness Connector Lighting Harness Connector HeaDLamp Harness Connector Rear electrical box Rear electrical
216. S 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 Engine oil should meet Rover specification RES 22 0L G4 or the European specification CCMC G4 and have a viscosity band recommended for the local ambient temperature range as shown in the following chart Where oils to these standards are not available reputable brands meeting American specification SG or SH should be used Note that the viscosity rating is made up of two numbers the first identified by a W suffix is the winter or low temperature viscosity grade and the second number the summer or high temperature viscosity grade i e a 20W 50 oil performs like an SAE 20 oil at low temperature and an SAE 50 oil at high temperature Engine Oil Viscosity Chart sw me sm mE MERI SE Ambient Temperature Range 15W 40 a 10 20 30 gt e ato 30 120 Capacity refill inc filter 4 5 litre 7 9 imp pt dry inc filter 5 0 litre 8 8 imp pt Difference between high amp low dipstick marks 1 0 litre 1
217. S 4 1 ri t LJ 6 4 5 l oo B H H _ 2 2 MT Jj Md X es E A YN YsSy Gy bn ae gt i119 4000 D 5 Miu 01 2 LIU eT t I La or at TN Wick lt Se Oy 12 a H 2 A H IIMS 1008 d ae eH fet e gt 4 E zz o pex IE wp p 0 4I e gt E SE i ef Afs B SH f aah te Su 121 SWIN CH ene Be Se fus z l or Se 5 d SUA E zen Cer SES Zen Wav p e ctu i 5 mcn 2 5A SH T lt m ot MAIS Paso cle is 2 4 lt gt D B o S 1 ext 2 a gt gt 7 d 72 gt 7 BS Eo m o E e E t E gt lt id lt a Dy IP 5 2 gt Y S gt u 5 _ x E m 5 S m 4 i eu k Gas E ee ee EE ES CEA o 5 au HONIG LINNOG D Zu qu Lew i Tu qn
218. S security module in order to allow the immobilisation function to operate Necessary if either the engine ECM or 5AS module is replaced iii Transmitter key matching Not applicable on Cobra cars To programme the 5AS module to recognise the signal from the transmitter keys Necessary if the transmitters are replaced iv User password changing or recharging v MEMS 1 9 engine management diagnosis see sub section EMN 3 Contents of the Lotus Check Too 00071346 The Lotus Check Tool 100071346 is supplied in a suitcase and contains the following items Scanner Tool with LCD display panel Printer Page 7 Lotus Service Notes Section MN Power Harness Adaptor Harness MEMS 1 9 Programme Card 5AS Security Programme Card Security Module Dongle Instruction Booklet Power harness Adaptor harness plugged into DLC amp switched to 5AS MEMS 1 9 programme card Scanner tool Printer To Connect Lotus Check To connect the equipment proceed as follows i Open the front and rear compartment lids ii Connect the power harness crockodile clips to the battery in the front compartment iii Plug the adaptor harness into the 16 terminal diagnostic link connector DLC next to the MEMS 1 9 ECU at the left hand side of the rear compartment and also connect to the power harness iv Select 5AS on the adaptor harness switch v Plug the power harness into the scanner tool and the printer
219. SERVICE NOTES LOTUS CARS LTD Norwich Norfolk NR14 8EZ England Telephone 01953 608000 Telefax 01953 608300 Part Number A111T0327J Lotus Cars Ltd 1996 Publication Part Number A111T0327J Lotus Cars Lid June 1996 This publication has been designed for use by Lotus Dealers familiar with general work shop 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 Introduction CONTENTS M111 ELISE Section Technical Data Engine TDL Vehicle TDM Chassis AF Bodycare amp Repair BM Body Fittings BN Front Suspension CG Rear Suspension DE Engine inc Rover publication RCL 0057ENG EE Engine Management EMN Transmission inc Rover publication RCL 0124ENG FH Wheels amp Tyres GF Steering HE Brakes JH Engine Cooling KF Fuel System LH Electrics MN Maintenance amp Lubrication OG Heating amp Ventilation PF Air Conditioning Heating amp Ventilation 2000 M Y PH Clutch QF Motorsport XA 340R Supplement 340R Exige Supplement Exige 2000 04 da
220. SL388 All LHD 340Rs were factory built with oil coolers The following procedure outlines oil cooler fitment to a RHD 340R recommended for use on race tracks or in conjunction with the 340ps tonne kit Kit Contents Oil Cooler A340E6025F 1 Oil Filter Housing A111E6146F 1 Gasket oil filter housing A111E6101F 1 Oil Filter A111E6038S 1 90 Connector oil pressure switch A111E6147F 1 Oil Pressure Switch A111E6099S 1 Hose oil cooler feed A340E0036F 1 Hose oil cooler return A340E6020F 4 Grommet cooler hose B111G6012F 4 Pillar Nut M6 oil cooler mounting A340E0034F 4 Setscrew M6x12 cooler fix A00027043F 8 Washer flat M6 A075W4013F 8 Clip open cooler hose fix A075W6229F 8 Pop Rivet P clip A075W6087F 8 Fitting Procedure 1 Remove the body topshell see sub section 340R B 2 Replacethe oil filter housing on the engine with the new housing which incorporates feed and return ports for the oil cooler hoses Fit the new filter Using a thread sealant screw the new adaptor elbow into the tapped hole on the underside of the housing and fit the new brown bodied oil pressure switch into the elbow note that the new switch is taper thread old switch parallel thread 3 Cut a pair of 32mm diameter holes for the cooler hoses the right hand outer wall of the radiator duct just ahead of the engine coolant hose aperture and another corresponding pair of holes in the rad duct inner wall 4 Position the oil cooler in
221. Service Notes manual Section EMM A limited range of trouble codes are available Trouble Code Description P0107 Manifold Absolute Pressure Circuit low input P0108 Manifold Absolute Pressure Circuit high input P0112 Intake Air Temperature Circuit low input P0113 Intake Air Temperature Circuit high input P0117 Engine Coolant Temperature Circuit low input P0118 Engine Coolant Temperature Circuit high input P0122 Throttle Position Circuit low input P0123 Throttie Position Circuit high input P0131 Oxygen Sensor Circuit low voltage P0132 Oxygen Sensor Circuit high voltage P0201 Injector Circuit Malfunction Cylinder 1 P0203 Injector Circuit Malfunction Cylinder 3 P0205 Injector Circuit Malfunction Cylinder 4 P0207 Injector Circuit Malfunction Cylinder 2 P0601 ECM Integrity Watchdog P0606 ECM Integrity Checksum P1100 Fuel Pump Relay or ciruit open P1101 Fuel Pump Relay or ciruit shorted P1106 Barometric Pressure Circuit range performance problem P1107 Barometric Pressure Circuit low input P1108 Barometric Pressure Circuit high input P1420 Battery Voltage Too high P1421 Battery Voltage Too low P1501 Resonator Valve Not closing P1502 Resonator Valve Not opening 2000 03 Lotus Service Notes Exige Intake System amp Resonator Valve A short intake manifold assembly incorporates individual inlet tract butterfly throttles operated via cable quadrant between cylinders 2 amp 3 Aglassfibre composite airbox bigger stil
222. TEERING WHEEL 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 To Remove Steering Wheel 1 Pull off the centre trim pad with horn button and disconnect the two horn leads Sa a EE EE EELER Page 2 Lotus Service Notes Section HE Column upper shroud 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 steer ing wheel as necessary to permit access Pull out the grommet from around the ignition switch and remove the three screws securing the lower shroud to the column If necessary disconnect or remove the trip panel lights control button and im mobiliser socket from the lower shroud Shroud mounting bracket Column lower shroud 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 Use a suitable steering wheel puller tool to
223. X6013S Breather kit inc breather rail blanking plugs amp idle stub blanks A340E6011S 1 litre breather catch tank A340K6007S 82 thermostat A340E0035S cooler kit RHD Exchange ECM 0 8 h Replace the standard ECM with the 190 BHP version and return the old unit to Lotus A surcharge will apply until the old unit is received Delete Intake Resonator Valve 0 6 hr Remove the air intake resonator valve and control mechanism including the vacuum reservoir and two solenoid valves Re plumb the MAP sensor Discard the secondary air cleaner at the airbox inlet and connect the intake trunking directly to the airbox with the primary air cleaner at the front end of the trunking which can be sited close to or connected to the air intake duct on the LH flank Take care when washing to avoid directing jet wash equipment into the intake duct blank off if necessary 101 Inlet Camshaft Pulley 2 5 hrs The standard engine inlet cam timing is 105 ATDC maximum opening point The modified pulley allows the inlet cam timing to be advanced by 4 to 101 MOP 1 Remove the timing belt top cover 2 the engine to align the timing mark the crankshaft front pulley with the safe position 45 mark 12 O clock on the timing belt lower cover Check that the camshaft pulley timing marks are aligned towards each other if not turn a further 360 3 Slacken the belt tensioner clamp bolt and remove tension from t
224. a top which supplies all four fascia vents PE2 CONTROL CABLES For access to the heater controls and input end of the cables the dash panels must be dismantled 1 Release the four screws securing the steering column shroud upper section turning the steering wheel as necessary to permit access 2 Pull out the grommet from around the ignition switch and remove the three screws securing the lower shroud to the column 3 Squeeze the dash panel centre plastic moulding top to bottom and pull out from the dash centre extru sion 4 Release the three screws securing the dash top and centre extrusions to support legs on the fascia top and unclip the panel from the fascia Note the two spring stee clips used along the top edge of the dash top extrusion to inhibit rattles Dash top extrusion Fascia top Plastic insert Spring steel clip panel n emu Dash centre extrusion Parts of bonded Dash lower extrusion chassis assembly Page 4 Lotus Service Notes Section PF _ Lotus Service Notes Section 5 Two identical slider control lever assemblies are used for the heat and distribution functions each being secured to the dash with two countersunk screws and nuts with the screw heads concealed by a graphic strip The ends of the solid wire inner control cables are joggled and are hooked into a hole in the control lever with the outer cable clamped to the baseplate with a barbed spring steel clip A si
225. ace door window glass 1 Remove the trim panel around the interior release handle Remove the two screws in the front edge of the finisher and unhook the finisher from the handle and door shell 2 Releasethe three screws securing the interior release handle and unclip the control rod from the mecha nism 3 Remove the door trim panel Unclip the cap from the window winder handle release the retaining screw and withdraw the handle Release the seven fixing screws and remove the door trim panel 4 Release the three M6 nuts securing the door glass to the lift channel and separate the glass from the channel 5 Donotattempt to withdraw the glass from the door without first removing the door glass inner waist seal or damage to one or both waist seals will result With the door glass lowered clear of the waist seals carefully pull the inner seal off the horizontal flange 6 Slide the door glass upwards and out of the door Refit in reverse order to removal Note that new door glasses are supplied complete with the stud carriers bonded to the lower edge but if a carrier should become loose or detached the old adhesive should be cleaned off the bonding surfaces cleaned with Betaclean 3900 A100B6008 and the following products used to rebond the carrier following the adhesive manufacturer s instructions Permabond Initiator INI 5 A000Z20043F Permabond Flexon F246 B089B6125V When re bonding ensure that the studs align with the holes
226. aces of gasket 6 Using assistance fit cylinder head on to cylinder block carefully locating ring dowels 7 Carefully enter cylinder head bolts in their original fitted locations DO NOT DROP Lightly tighten bolts K8 Tighten cylinder head bolts progressively in sequence shown to 20 Nm Use felt tip pen and mark position of radial mark on each bolt head Tighten all bolts in sequence shown through 180 Tighten all bolts in sequence shown through another 180 and align mark CAUTION If any bolt is overtightened back off 90 and re align 70 OVERHAUL ENGINE Hesse K16 9 Temporarily fit timing gears to camshafts fit but do not fully tighten bolts NOTE This will enable camshafts to be rotated in order to enable remaining bolts to be tightened Early engines bolts 1 and 2 Later engines fitted with modified camshafts bolts 3 and 4 10 Tighten cylinder head bolts progressively in sequence shown to 20 Nm Use a felt tip pen and mark position of radial mark on each bolt head Tighten atl 10 bolts in sequence shown through 180 Tighten all bolts in sequence shown through another 180 and align mark CAUTION If any bolt is overtightened back off 90 and re align 11 Upon completion of tightening sequence position camshafts with inlet pin at 4 o clock and exhaust pin at 8 o clock remove timing gears CAUTION Ensure camshafts do not rotate when gears are removed 1
227. 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 gaps around the door hinge post and striker plate and smooth with a spatula 10 Clamp the panel into position until the adhesive has cured see sub section BM 5 11 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 12 Refit the dash panel front and rear clamshells doors both wheelarch liners and other components as necessary Page 17 E Lotus Service Notes Section BM BM 10 REAR BULKHEAD amp CAPPING RAIL The rear bulkhead and capping rail are bonded to the top surface of the rear chassis and to the rear ends of each sill panel Removal or replacement of these panels requires that at least one of the sills be removed When fitting the angular position near vertical of the panels is best achieved if fitted immediately before the sill panel s in order that the sill to bulkhead joint be allowed to define the alignment 1 With at least one of the sill panels removed the adhesive bead must be cut to free the panels from the roll over bar stays sill panel rear ends and chassis 2 Prepare the joint faces of the new panels chassis and sills in accordance with sub section BM 5 3 Locate the capping rail around the roll over bar stays before applying a bead of Betaseal
228. adiator matrix by the hinge elbow if the hinge blade should be inadvertently pressed downwards Bonnet panel plinth Shim plates Hinge blade Thrust washers Pivot screw Clamshell gutter Hinge bracket Bonnet Hinge A hinge bracket is bonded and rivetted to the front gutter of the clamshell and incorporates two pivot lugs The alloy hinge blade is bolted to the bonnet via three M6 screws with tapped bobbins laminated into plinth on the underside of the bonnet panel A tube welded to the front end of the hinge blade is tapped to take the two M6 pivot screws which use plastic pivot bushes and steel thrust washers to connect the blade to the hinge bracket lugs Disassembly of the hinge is possible with the clamshell in situ but removal of the clamshell provides easier access 3 ENGINE COVER LID The engine cover lid is an aluminium pressing which incorporates hot air outlet grilles for the engine bay bonded to the lid with Betamate adhesive and the mounting for the radio aerial A composite box section re rg ENEE EE EE ECCO AC Page 5 Ce Lotus Service Notes Section BN reinforcement channel is bonded to the front underside of the panel and incorporates three M6 tapped bobbins for the hinge blade attachment and a composite plinth is provided at the rear for the latch striker pin Latch Mechanism The single latch is mounted at the cen tre of the rear edge of
229. aft inboard joints see Sub Section FH 4 Use new circlips on the spigots of the inboard C V joints and follow the procedure in Sub Section FH 4 to refit 6 TRANSMISSION OVERHAUL The overhauling of the Rover supplied type PG1 transmission is detailed in Rover publication RCL 0124ENG Note that a conventional bevel gear differential is used for the Elise application Special tools are available through Lotus under the following part numbers Transmission Special Tools Description Driveshaft Removal Wedge Adaptor Plate bearing puller Driver Handle bearing dolly Replacer Dolly input shaft oil seal Slide Hammer output shaft bearing remover Adaptor output shaft bearing remover Driver Handle bearing dolly Replacer Dolly output shaft bearing Circlip Pliers bearing access plug Thrust Pad bearing puller Hex Socket M14 access plug Anti Spread Plate input output shafts Replacer Dolly differential bearings Replacer clutch release shaft inner bush Replacer clutch release shaft outer bush Clutch Alignment Mandrel Blanking Plug driveshaft output Replacer Dolly output seal RH amp type LH Replacer Dolly output seal B type LH Seal Protector output shaft seals Lotus Part No T000T1276 T000T1291 T000T1292 T000T1293 T000T1294 00071295 TOOOT 1296 T000T1297 T000T1298 T000T1299 TOOOT 1300 00071301 TOOOT 1302 TO000T 1303 TOOOT1304 T000T1277 000 1385 000 1388 000
230. agement components are as standard Elise The OBD2 On Board Diagnostics version 2 connector socket is located within the electronics box on the cabin rear bulkhead For fault diagnosis the Tech 1 tool including the Esprit V8 cartridge should be plugged into this socket and any trouble codes read in conjunction with Service Notes manual Section A limited range of trouble codes are available Trouble Code P0107 Manifold Absolute Pressure P0108 Manifold Absolute Pressure P0112 Intake Air Temperature P0113 Intake Air Temperature P0117 Engine Coolant Temperature P0118 Engine Coolant Temperature P0122 Throttle Position P0123 Throttle Position P0131 Oxygen Sensor P0132 Oxygen Sensor P0201 Injector Circuit Malfunction P0203 Injector Circuit Malfunction P0205 Injector Circuit Malfunction P0207 Injector Circuit Malfunction P0601 ECM Integrity P0606 ECM Integrity P1100 Fuel Pump P1101 Fuel Pump P1106 Barometric Pressure P1107 Barometric Pressure P1108 Barometric Pressure P1420 Battery Voltage P1421 Battery Voltage P1501 Resonator Valve P1502 Resonator Valve Page 12 Description Circuit low input Circuit high input Circuit low input Circuit high input Circuit low input Circuit high input Circuit low input Circuit high input Circuit low voltage Circuit high voltage Cylinder 1 Cylinder 3 Cylinder 4 Cylinder 2 Watchdog Checksum Relay or ciruit open Relay or ciruit shorted Circuit range performance
231. ain bearing Bearing diametric clearance is controlled by three grades of selective shell bearing Oil grooves are provided in the upper halves of main bearings No 2 3 and 4 to supply oil via drillings in the crankshaft to the connecting rod big end bearings 18 DESCRIPTION AND OPERATION ENGINE K8 engine lubrication system 12 0566 DESCRIPTION AND OPERATION 19 ENGINE K16 engine lubrication system Get 10 39 ere D mee 2 ef e CG F 12 1758 Non VVC camshafts illustrated 20 DESCRIPTION AND OPERATION Lubrication The lubrication system is of the full flow filtration forced fed type The oil sump is of either pressed steel or alloy manufacture Pressed steel sumps are sealed to the bearing ladder using a positively located gasket incorporating compression limiters Alloy sumps are sealed to the bearing ladder with a bead of sealant applied to the sump flange Oil is drawn via a strainer and suction pipe 1 in the sump into the crankshaft driven oil pump 2 of the trochoid type which has an integral pressure relief valve 3 excess oil is diverted into the intake 4 of the oil pump Oil is pumped through the full flow cartridge type oil filter 5 mounted on an adapter attached to the oil pump housing The low oil pressure sensor 6 is also screwed into the adapter and registers the oil pressure in the main oil gallery on the out low side of the filter The main oil galler
232. ake and opens the recirculation port to draw air from the interior of the car via the four groups of holes in the chassis footwell front wall This facility should be used when maximum refrigeration is desired or in heavy traffic to minimise the induction of exhaust fumes The amber tell tale in the switch button is backlit when the sidelamps are switched on to help locate the switch and brightens when the button is pressed Fan Speed The left hand rotary switch provides three fan speeds to boost air circulation Turned fully counterclockwise the fan is off some airflow will be generated by ram effect which is dependent on vehicle speed but for controlled output a fan speed should be selected 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 2000 04 EE Lotus Service Notes Section PH Temperature The temperature control is a sector rack and pinion operating a control cable linked to the air blend flap in the heater housing Turned fully counterclockwise the flap is moved to direct all airflow to by pass the heater matrix At this position the rack sector operates an electrical microswitch which in conjunction with a solenoid valve and pneumatic water valve closes off the hot water supply to the matrix The water valve is located at the bottom right hand side of the engine bay If air cooling is required use this t
233. ake fluid should be renewed every twelve months The fluid may be changed and bled of air using pressure or vacuum assisted equipment or standard manual techniques Each brake caliper is provided with a bleed nipple for this purpose The clutch release system hydraulic fluid should be changed at the same time JH 3 FRONT BRAKE PAD REPLACEMENT Pad thickness may be checked with the wheel removed without disturbing the caliper Alloy discs Iron discs Standard pad thickness excluding backplate 10 0 mm 9 0 mm Minimum pad thickness excluding backplate 2 5 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 different brake pads are used for aluminium and iron discs Aluminium discs These pads are identified by a stencilled number on the backplate commencing with BXD If desired self adhesive anti squeal overlays A111J0122F may be fitted to the pads after approx 0 75mm of wear has taken place but some loss of pedal feel will be incurred Iron discs These pads are factory fitted with anti squeal overlays and marked Brembo 07 5505 30 40 The overlay is assymetric and is marked with a directional arrow ensure the arrow on all four pads points in the direction of forward disc rotation 1 Toremove the brake pads Remove the securing split pin and withdraw the lower of the two pad retaining pins taking precautions to restrain the anti rattle spring Remove the second
234. al 4 Check pinion shaft for wear 5 Check speedometer drive gear teeth for wear or damage replace as necessary Differential Housing 1 Check housing for damage check that locating dowels are fitted check clutch release shaft bushes for damage or wear and that shaft is free to turn replace if necessary using the following procedure Remove EL be m un 2 Outer bush Using a hacksaw blade carefully cut a longitudinal slot opposite the split in the bush prise bush out of differential housing 3 Inner bush Carefully prise inner bush out of differential housing 37 0694 OVERHAUL 17 MANUAL GEARBOX Refit 37 0695 4 Inner bush Using tool 18G 1723 1 drift inner bush into differential housing 37M0696 5 Outer bush Using tool 18G 1723 2 drift outer bush into differential housing CAUTION Ensure end of tool 18G 1723 2 A is located in inner bush 6 Gearboxes fitted with output shaft bearing retainer plate Remove all traces of Patchlok compound from output shaft bearing retainer plate holes using an M6 tap CAUTION Ensure bolt holes are thoroughly cleaned eae PETIT pL aa n A SE rm Pas et ESTE EE AS RR y EE IS TE NES TL DE IES LIE RITE EE EASES 18 OVERHAUL REVISED 12 97 COMPONENT ASSEMBLING Differential 1 Assemble planet gears and original thrust washers 2 Fit sun gears and original thrust washers if fitted 3 Rotate gears a
235. amps 15 Remove slave bolts securing VVC housings to camshatt carrier 16 Remove front and rear inlet camshafts and VVC housings from camshaft carrier CAUTION If new VVC housing gaskets have been fitted do not remove timing plates 18G 1770 1 and 18G 1770 2 46 OVERHAUL 17 18 19 Measure widest portion of Plastigage on each inlet camshaft journal on camshaft carrier Inlet camshaft bearing joumai clearances 25 mm diameter journals 0 025 to 0 060 mm Service limit 0 1 mm 40 mm diameter journals 0 030 to 0 070 mm Service limit 0 1 mm Measure widest portion of Plastigage on each exhaust camshaft journal Exhaust camshaft bearing clearance 0 060 to 0 094 mm Service limit 0 15 mm If bearing clearances on any camshaft are excessive fit new exhaust camshaft or inlet camshafts and VVC assemblies and repeat check If clearances are still excessive replace cylinder head and camshaft carrier assembly CAUTION If replacement exhaust camshaft is to be fitted ensure it is correct for engine being worked on NOTE Inlet camshafts are only supplied with VVC mechanisms as an assembly 20 Remove exhaust camshaft from cylinder head 21 Remove all traces of Plastigage using an oily rag ENGINE Timing gears VVC engines CAUTION If gears have been subjected to prolonged exposure to oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean
236. anel To unlock the cap insert the key turn 14 clockwise counterclockwise and then to avoid the possibility of paint damage withdraw the key Remove the cap by unscrewing counterclockwise Refit the by screwing clockwise into the filler neck and tighten until the ratchet mechanism clicks at least three times The cap is now automatically locked and requires the use of the key to be removed er EE II 9 ODE CO E EE LANES CHT CARENCCT EUN IIMEUNCNNCGECTENNLIE I FECHA NEC E RN GN pU E Page 3 8 Lotus Service Notes Section LH Filling Procedure Insert the pump nozzle fully into the neck and fill until the first time the auto shut off mecha nism 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 fuel tank capacity is 36 litres 8 0 imp gal LH 3 PRECAUTION The fuel line between pump and injector rail and the injector rail itself contain pressurised fuel both when the engine is running and after switching off This feature aids engine starting by reducing the time needed to build up operating fuel pressure and inhibiting the formation of vapour pockets in the supply line of a stopped hot engine i minimise the risk of fire and personal injury reliev
237. ant Oil 8 16 Compressor PH 9 16 Condenser PH 8 16 Receiver Drier PH 11 20 Expansion Valve PH 12 21 Evaporator Unit PH 13 22 Heater Blower Fan Assembly PH 14 23 Exige A C Circuit Diagram 24 2000 04 SR S Lotus Service Notes Section PH Heater matrix Water feed pipe along outside of RH chassis siderail Water valve Water return pipe along outside of Water return to LH chassis siderail engine side of thermostat Coolant re circulation pump Refrigerant Circuit Receiver drier Feed amp return pipes along outside of RH Service valves chassis siderail Compressor 2000 04 DE Lotus Service Notes Lotus Service Notes Section PH 1 GENERAL DESCRIPTION This section covers Elise and Exige models built in year 2000 fitted with air conditioning For cars with a heater alone refer to section PF For cars built prior to 2000 and fitted with a c alone no heater refer to section PG Air Conditioning 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 radia
238. any driver initiative the Meta M36 T2 immobiliser will passively immobilise the engine s cranking and running circuits about 20 seconds after the ignition has been turned off The immobilised state will be indicated by the immobiliser tell tale on the fascia top ahead of the instruments blinking once every two seconds To mobilise the engine press once the button on the transmitter key head with ignition either on or off Mobilisation will be acknowledged by the tell tale being extinguished Upgraded Security System For enhanced protection from theft and vandal damage the Elise 340R may be specified factory built with a Meta vehicle security system which incorporates the following features ngress protection using sensing switches on the front access panels and engine lid Selectable cockpit intrusion sensing using a microwave sensor Automatic passive engine immobilisation to prevent the engine from being started Self powered siren to maintain protection if the vehicle battery is disconnected Dynamic coding of the transmitter keys Each time the transmitters are used the operating frequency is randomly changed to guard against the possibility of code copying Passive Immobilisation In order to provide a measure of automatic vehicle security independent of any driver initiative the Meta M36 12 immobiliser will passively immobilise the engine s cranking and running circuits about 20 seconds after the
239. ar Convolute sleeving r The four fuel injectors are fitted between the pressurised fue rail and the inlet manifold Each injector comprises a solenoid operated needle valve and a specially designed nozzle to ensure good fuel atomisation The ECM energises the injectors under engine run conditions and provides an earth signal for the period the injectors are required to be open referred to as pulse width spraying fuel onto the back of the inlet valves Standard engines use group injection where the fuel injectors are activated in pairs 1 with 4 and 2 with 3 whereas VVC engines use fully sequential injection with each injector activated individually During cranking when the engine speed is below approx 400 rpm the ECM increases the pulse width dependent on coolant temperature to aid starting and on VVC engines operates the injectors in group mode To prevent flooding the ECM periodically inhibits the operation of the injectors during extended cranking Pag EG Lotus Service Notes Section EMN Do not attempt to remove the pressure regulator valve from the fuel rail The valve is supplied only as an assembly with the rail The fuel rail is removed from the engine complete with the four fuel injectors 1 De pressurise the fuel system and disconnect the battery 2 Remove the breather hose between intake plenum and cam cover and the breather hose between the throttle body and cam cover 3 Disconnect the vacuum hose
240. ar section to supply the rear brakes A translucent fluid reservoir surmounting the cylinder services both front and rear circuits and also via a linking hose the clutch master cylinder A fluid level sensor is incorporated into the filler cap and lights a fascia tell tale lamp if the level becomes dangerously low The parking brake ratchet lever is mounted between the seats and uses a balancing linkage to actuate individual contro cables to each rear caliper Adjustment of the caliper mechanism to compensate for brake pad wear is automatic The brake should be applied by pulling upwards firmly and fully to engage the maximum number of ratchet clicks 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 vigouous 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 due to temperature change 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 After fitting new brake discs or pads the braking effic
241. arated in order to minimise heat transmission from the heater pipe to the clutch fluid Bleed the clutch system of air using conventional techniques and refit all panels removed for access QF 4 CLUTCH ASSEMBLY The clutch assembly comprises the friction plate clutch cover assembly pressure plate diaphragm spring and release bearing For access to the clutch assembly the transmission must first be removed with or without the engine situ Access is improved if the rear topshell is removed Removal of clutch assembly 1 With the car supported on a wheel free lift Remove the LHR lower wishbone Release the bolt securing the spring damper unit to the lower wishbone Release the wishbone to chassis pivot bolts Release the parking brake cable ties and swing the wishbone out of the way Release the RHR suspension toe control link from the hub carrier and release the top ball joint plinth from the hub carrier taking note of the camber adjustment shimplates in order to allow withdrawal of the driveshaft from the transmission Release both driveshaft inboard C V joints from the transmission using special wedge tool T000T1276 on the RH side and or applying a shock pull to the C V joint body using a slide hammer with a forked end Fit blanking plug T000T1014 into the transmission to limit the amount of transmission oil loss CAUTION Do NOT attempt to remove an inboard joint from the transmission by pull
242. ards rear of cylinder head record reading obtained to give valve stem to guide clearance B Repeat above procedures for each valve in tum OVERHAUL 51 ENGINE K Valve stem diameter Inlet 6 960 to 6 975 mm Exhaust 6 952 to 6 967 mm Valve guides Inside diameter B 7 000 to 7 025 mm Valve stem to guide clearance C Inlet 0 025 to 0 065 mm Service limit 0 07 mm Exhaust 0 033 to 0 073 mm Service limit 0 11 mm 16 Valve stem diameter Inlet 5 952 to 5 967 mm Exhaust 5 947 to 5 962 mm Valve guides Inside diameter B 6 000 to 6 025 mm Valve stem to guide clearance C Inlet 0 033 to 0 063 mm Service limit 0 07 mm Exhaust 0 038 to 0 078 mm Service limit 0 11 10 Renew valves and guides as necessary 52 OVERHAUL Vaive guides renew 1 Support cylinder head face down on wooden blocks 18G 1576 1 18G 1576 3 8RM 0077 A 2 Position tool guide 18G 1576 3 in tappet bore and drift out valve guide using tool daft 18G 1576 1 NOTE Retain valve guides in their fitted ZS order A B D LA 12M0007 3 identify type of valve guide fitted A Standard production C Production oversize NOTE Two replacement sizes of valve guide available sizes and D replace original guide A with B and original guide C with D 18G 1576 1 18G 1576 3 KB 18G1576 4 16 18G1576 2 BRM 0076 A NOTE Cylinder h
243. ark topshell deck with positions of the two sockets and drill and rivet into place with black rivets 6 Pullthe cover around the rest of the cockpit and mark the postions of the remaining sockets as shown in the diagram Take care when drilling the topshell to limit penetration so as not to damage any parts below e g harnesses or hoses Rivetthe sockets to the body and fit the tonneau routing the drain tubes at the front beneath the instrument rail and into the passenger footwell where excess water can drain away By unzipping the driver s side of the tonneau and stowing the rolled section behind the driver s seat the car can be driven with some interior protection Note that the rear screen should be in place when driving in this configuration A post socket Topshell socket Drain tubes Driver s zip Velcro strap b315 2000 02 x Lotus Service Notes Section XA 340R EXCHANGE 190 BHP A340 LSL394 The 190 BHP exchange engine ECM is designed for track use only and includes the following features Modified fuelling and ignition maps Open loop fuelling Rpm limit raised from 7 800 to 8000 rpm Rad fan switching point lowered from 104 C to 92 C The ECM is calibrated to optimise performance with the following performance parts fitted as a package Deletion of intake resonator valve A340E0011S 101 inlet camshaft pulley LOTAC05066S Stainless steel catalytic converter replacement pipe A340
244. arm tell tale will be extinguished Intrusion Sensing A hyperfrequency radar detector mounted at the rear of the centre tunnel is able to detect substantial movement within the cockpit and trigger the alarm in the event of unauthorised intrusion The range and sensitivity of the intrusion sensor may be adjusted if necessary see page 6 If an animal is to be left in the vehicle when the alarm is armed it is necessary temporarily to switch off the intrusion sensing by the following procedure Arm the system the usual way by pressing once the large button on the transmitter E Within 40 seconds press once the smaller button on the transmitter This action will be acknowledged by a single buzz of the buzzer Note Intrusion sensing will automatically be reinstated the next time the alarm is armed Do not inhibit operation of the radar detector by placing bags or large objects against the sensor Summary of Alarm Normal Operation In normal use whenever leaving the car close both lids lock the doors using the key and press once the transmitter large button to arm the alarm acknowledged by two hazard lamp flashes and the alarm tell tale flashing Check that two hazard flashes occur and not one see below On return to the car whether or not the alarm is armed again press once the transmitter large button This will either disarm the alarm or if the alarm was not armed the passive immobilisation will be switched off In both case
245. ars may be reversed B Slot Rating Circuit 13 20 Radio 13 14 20A Cigar lighter 14 15 5A Sidelamps LH 15 16 5 Sidelamps RH 16 50 Lighting N amp NU cables 50 Ignition switch amp NW cables 40A Maxi ons fuse early cars On cars prior to Feb 97 fuses for the engine 10A Littel management system 40A and fuel pump 10A are fuse located on the LH side panel in the rear luggage com partment to the rear of the engine management ECM For later cars see also sub section MN 10 sii Page 15 E Lotus Service Notes Section MN The wash wipe module and hazard flasher relay are mounted behind the passenger side chassis scuttle beam For the location of the vehicle alarm system components see sub section MN 1 Engine management components are detailed in Section EMN Fuse colours 2A Black 10A Red 3A Violet 15A Light Blue 4A Pink 20A Yellow 5A Orange 25 Clear 7 5A Brown Component Location Windscreen washer bottle Radiator fan motor Fusebox A7 4 relay station 5 Fusebox B Lucas 5AS security module Wash wipe module amp Hazard relay Wheel speed sensor Engine management A Inertia switch ECM 12 Engine management fuses amp DLC 16 Lotus Service Notes Section MN 5 AUDIO EQUIPMENT All cars are provided with a radio ISO connector and aerial lead which on cars not built with an au
246. ase the evaporator unit out of the chassis 7 Before refitting the unit in reverse order to the above first check that the battery earth cable is correctly secured to the chassis earth point at the left hand side of the climate chamber and on LHD cars is correctly routed across the chamber floor to the passenger side front corner Also check that the battery breather pipe is routed through the aperture at the bottom centre rear of the chamber Feed the evapo rator drain hose through the aperture when installing the evaporator unit HIE Battery tray Evaporator unit 2000 04 CS Lotus Service Notes Section PH PH 14 HEATER BLOWER FAN ASSEMBLY The heater blower fan assembly comprises the heater matrix air blend flap and blower fan and motor contained within a rivetted plastic housing fitted the driver s side of the chassis climate chamber A pair of resistors used in the fan speed switch circuit are mounted on an aluminium heat sink bracket and secured to the chassis at the drivers side front corner of the climate chamber To remove the heater assembly the evapo rator assembly must first be removed 1 Remove the evaporator assembly sub section PH 13 2 Take suitable precautions to protect paintwork from coolant splashes before releasing the two heater hoses from the matrix and plugging both hoses to minimise coolant loss 3 Remove the trunking between the fan scroll and distribution plenum 4 D
247. assis side rails and release both backstays from the aerofoil mounting plates Lean the roll over bar forwards to allow sufficient clearance for topshell re moval 5 Remove both outside mirrors and disconnect the side repeater lamps 6 Remove the front body access covers and disconnect the front harnesses 2 at the outboard rear corner of the driver s side access hatch Topshell Height adjustable Mirror fixing Gutter Fixings to fixing near wiper to screen frame fixing sill panel spindle Fixing to toe panel Fixings to wall to sill panel Fixings to cockpit subframe panel Rear wall to topshell Page 6 10 11 12 13 14 a 3408 Lotus Service Notes 340R Remove the single fixing securing the front body spine to the plinth below the wiper spindle Remove the front undertray Remove the two screws at each side securing the topshell to the underside of the side sill behind the front wheels and the single adjacent screw securing the topshell leg to the toe panel Remove the two nuts each side securing the topshell to the cockpit coaming From the front edge of the engine lid gutter remove the three socket head fasteners From inside the engine bay remove the two nuts securing the topshell to each top rear end of the sill panel Release the fixing securing each side of the engine bay rear wall to the subframe Protect or remove the front mudguards and the sides of the wi
248. astomeric adhesive Right hand side engine bay air intake duct lectrical amp Interior Battery Replace the standard battery with the lightweight race battery and mounting bracket Race light conversion Change the two outermost bulbs in the CHMSL to 3W to become the racelight acti vated with the ignition The centre two bulbs remain as stop lamps Fit the link lead supplied in the kit as directed by the specific instructions supplied LSL390 Remove Alarm controller siren and bracket microwave sensor immobiliser and alarm harness Plug bridging link into immobiliser connector Footwell divider alloy panel Cockpit divide switches mounting panel and strut Plug bridging link into sidelamp switch connector Gear lever handbrake shroud with trickle charger socket Fit standard Elise gear lever shroud Auxiliary power sockets mounting panel and harness Hazard switch and fit grommet Column switches and fit alloy blanks using elastomeric adhesive Rear indicator and tail lamp assemblies inc mounting brackets and harnesses Licence plate lamps and harness Engine cover lid alarm switch and harness Top shell harness Relays main aux dip horn heated screen and relay cover Fuses 2 4 5 6 9 10 14 16 17 18 20 21 22 and fuse cover Passenger footrest Luggage net Floor mats Interior mirror Fix the alloy blanking panel to the aperture in the rear bulkhead electronics cover using double sided tape or rivets Miscellane
249. at the left hand side of the rear luggage compartment protected by a rivetted cover The microwave sensor is secured to the cabin rear bulkhead between the seats Note that the Lucas 5AS module is still used as with the base alarm system in order to communicate with the engine management ECM The 5AS module is mounted behind the fascia on the steering column upper Page 6 Section MN Lotus Service Notes Section MN bracket and may be accessed after removal of the column shrouds and instrument pack see sub section 12 Front lid microswitch Alarm system keys Immobiliser touch key Rear lid microswitch controller Buzzer unit micro switch Override switch Microwave unit Immobiliser module MN 2 LOTUS CHECK SCANNER TOOL In order to provide for communication with the 5AS vehicle security system electronic control module a hand held electronic scanner tool Lotus Check part number TO00T 1346 may be plugged into a special 16 terminal harness connector socket known as a Data Link Connector DLC located next to the engine man agement ECM at the left hand side of the rear luggage compartment The Lotus Check tool allows the following operations to be pertormed i Systems Check Not applicable on Cobra cars Checks door switches and immobilisation function ii matching To programme the engine management ECM to recognise the coded signal from the 5A
250. at the unit should be renewed Thinly coat the cylinder bore with ATE Brake Cylinder Paste or ATE Brake Assembly Spray or a similar product to facilitate assembly and prevent corrosion Before assembling the seals onto the pistons note that three different seals are used with the part number printed on the lip of each seal Primary seal 03 3301 1933 1 Secondary seal 03 3301 1934 1 Grooved seal 03 3402 1901 1 Grooved seal Secondary seals 10 11 12 13 14 Primary seal Primary seal Assemble the front piston Fit a primary seal 03 3301 1933 1 into the front groove of the piston with the lip facing forwards Fit the support ring onto the piston nose to retain the seal and form a seat for the cylinder front spring Fit a pair of secondary seals 03 3301 1934 1 into the two grooves at the rear end of the piston with the lip of the front seal facing forwards and the lip of the rear seal facing rearwards Assemble the rear piston Fit a grooved seal 03 3402 1901 1 into the rear groove with the lip facing forwards Fit a primary seal 03 3301 1933 1 onto the front of the piston with the lip facing forwards Fit the spring support ring onto the piston spigot spring and stop sleeve and compress the spring to enable the retaining screw to be fitted and tightened Thinly coat all piston seals and the piston shoulders with ATE Brake Cylinder Paste or ATE Brake Assembly Spray or similar Fit the front
251. atch mechanism 6 Support the door shell before removing the two 8 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 7 Refit the bracket in reverse order to removal BN 12 INSTRUMENT BINNACLE amp DASH PANEL Dash end finisher Dash support legs VA T SS N CR Coin 1 4 Fascia top demist duct Plastic insert mouldings Dash top extrusion Dash centre extrusion Dash lower extrusion Page 22 Lotus Service Notes Section BN The instrument cluster is mounted via a combination of brackets off the steering column to scuttle mounting bolts with the instrument cowl mounted onto the top of the cluster The dash structure principally consists of three aluminium alloy extrusions upper centre and lower which link together horizontally to join the chassis scuttle beam to the fascia top demist duct All three sections are interrupted by the steering column The longer section of the dash centre panel houses the climate controls and audio aperture and the shorter section outboard of the steering column the row of push switches A plastic insert moulding surrounds each of these controls The upper dash panel extrusion is treated with Senotex textured paint as is the fascia top and inside surfaces of the windscreen surround To Replace Instrument Pack eol Fo
252. ation selectable microwave intrusion sensing door bonnet and boot lid sensing a self powered siren and dynamic coding of the transmitter frequency Cars with this level of alarm may be identified by the red and blue transmitter buttons and the microwave unit mounted on the rear bulkhead between the seats Whichever system is fitted one of the two battery powered electronic transmitter keys provided should be kept safe for use in an emergency and the batteries of both keys renewed at six monthly intervals to ensure continuity of operation Vehicle Security Alarm Lucas 5AS Standard Fitment When armed the vehicle alarm system enhances theft protection of the car by pulse sounding the horn if either door is opened or the ignition circuit is energised Additional protection is provided by an immobilisa tion feature which disables the engine cranking and ignition circuits when the alarm is armed whilst passive immobilisation ensures that this feature functions automatically under certain conditions see below Passive Immobilisation Engine cranking and running are disabled automatically 30 seconds after the follow ing sequence of events The ignition is switched from on to off The driver s door is opened A warning that immobilisation is in effect is provided by the Alarm tell tale in the instrument pack flashing on once per second continuously lit if a door is open In order to mobilise the engine press once the smooth b
253. attery Leads The positive battery cable on both right and left hand drive cars is routed through the left hand end of the scuttle baffle panel and down ahead of the door hinge post to run along the outside of the chassis side rail to the engine bay where it connects to the starter motor The cable run is inaccessible inside of the body sill panel and so must be fitted and secured with its saddle tie wraps before bonding a new sill panel to the chassis The negative battery lead connects via an M8 thread insert to the inboard side of the chassis rail at the bottom LH side of the heater battery well on both right and left hand drive cars Page 19 Lotus Service Notes Section MN Positive batte Starter terminal f solenoid i terminal Earth Points There are only two earth connections to the chassis one at the front for the battery earth lead and one at the left hand side of the engine bay for the engine earth braid and rear harness earthing requirements At both points the anodised surface treatment must be removed from the chassis before an M8 Pulsert is fitted with a special stepped washer being used to clamp directly against the chassis surface After assembly coat the chassis and cable terminals with petroleum jelly to protect from corrosion Engine management us N ve binding post Chassis front earth Cylinder block M connection earth point Special Battery earth stepped lead Engine
254. away from its Velcro fastening From the access thus provided release the clamshell front fixing from the inside of the B post area 12 Remove the two screws securing the lower front edge of the clamshell B post Page 9 Section BN Rear Clamshell Fixings Clamshell gutter SN 9 No plate Upper B post fixing Lower B post fixings Fixing to sill X 13 Release the two fixings securing the front of the clamshell lid gutter to the rear bulkhead panel and the single screw each side fixing the gutter to the boot bulkhead if fitted 14 Withdraw the clamshell from the car 15 Refit the clamshell in the reverse order to disassembly Mirror housing BN 6 DOOR MIRRORS The manually adjustable plastic housed door mirrors 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 poten tial for personal injury or vehicle damage Replacement of mirror glass The mirror glass is contained in a plastic Mirror glass and surround surround which is clipped into the housing in or der to provide for convenient and inexpensive replacement Page 10 Lotus Service Notes Section remove glass pull back the boot between mir
255. b and locate over the wheel studs 5 Apply Permabond A131 A912E7034 to the threads of the caliper fixing bolts Fit the caliper over the disc and secure to the hub carrier with the two bolts Note that the outermost of the alternative fixing holes in the hub carrier are used Tighten to 45 Nm 33 Ipf 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 caliper to enable the disc to be withdrawn from the hub Page 9 Lotus Service Notes Section JH 7 BRAKE MASTER CYLINDER The tandem brake master cylinder is mounted in the front compartment and is secured to the pedal box by two 8 bolts To remove the unit proceed as follows 1 Syphon fluid from the reservoir to reduce spillage 2 Disconnect the clutch master cylinder supply hose from the reservoir and plug the hose 3 Release the three brake pipes from the master cylinder and plug the pipes and ports 4 Release the master cylinder from the pedal box The top fixing bolt uses a Nyloc nut and flat washer on the inside of the box The lower fixing bolt uses a captive nut plate within the pedal box To Replace Seals 1 Thoroughly clean the exterior of the master cylinder assembly before commencing in a clean environ ment any dismantling
256. be checked with the appropriate organising authority Note that the tyre tread pattern is directional with the correct rotation marked by an arrow on the sidewall The potential chassis loadings provided by this tyre require that it be used only in conjunction with the sport road spring and damper set lowered ride height specific suspension geometry with increased negative camber uprated front anti roll bar and Uniball rear toe link kit The tyres should be mounted on factory approved Elise race wheels 6J front 8J rear in order to provide good tread stability for ultimate performance Tyres Tyre designation Yokohama A038 R Size front 195 50 R15 82V K 5243 rear 225 45 R16 89W K 5244 Pressure cold front 1 6 bar 23 Ib in rear 1 7 bar 25 Ib in Suspension Geometry Refer to sub section XA 8 to set the chassis to the lowered ride height of 100 110mm front rear and to set the steering rack height and rear bump steer shimming The following suspension geometry setting is recom mended for dry circuit use Specification Tolerance Max difference side side Front Camber 1 8 0 19 0 2 0 2 Front Caster 3 8 0 2 0 2 Front Toe 0 5mm toe out overall 0 2mm 0 Rear Camber 2 72 0 22 0 2 0 2 Rear Toe 2 5mm toe in each side 0 2mm 0 t may be necessary to machine the top ball joint plinth in order to attain sufficient negative camber 2000 02 Page 35 Lotus Service Note
257. 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 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 of the panels is not freely available 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 structural repairs should not generally be considered Note that if damage is such as to require replacement of the chassis replacement chassis assemblies are provided already jig assembled with the bonded body panels of rear bulkhead and capping rail sills wind screen frame and front crash structure Page 5 8 y Lotus Service Notes Section BM 5 BODY PANEL BONDING MATERIALS The materials used for bonding the body panels are manufactured by Gurit Essex and in order to main tain the structural integrity of the vehicle and in the case of the front crash structure the safety it is most important to
258. ble which NOE equal thickness required Fourteen circlips are Differential Pinion Gear Backlash Check and available ranging from 0 5 mm to 1 15 mm Adjust thick in incrernents of 0 05 mm CAUTION No more than two circlips may 3 be fitted it is not always possible to select the exact thickness of circlips required Remove bolts securing gear case remove gear case Remove input shaft assembly Remove input shaft bearing from differential housing using a soft metal drift 37M0171 1 Position differential assembly with bearings located in V blocks 2 Fit both inboard drive shaft joints to align gears Assemble a DT gauge with stylus of gauge contacting one of the planet gears zero the gauge Measure and record planet gear backlash Repeat procedure for other planet gear Compare backlash figures obtained with the following Planet gear backlash 0 05 to 0 15 mm 7 lf backlash is not as specified remove planet gears measure thickness of original thrust washers and from figures obtained calculate thickness of thrust washers required to give correct backlash 3 e gt CAUTION Thrust washers selected must be of equal thickness and are available from 0 70 to 0 90 mm thick in increments of 0 20 mm 8 Fit selected thrust washers secure pinion shaft with a new pin REVISED 12 97 OVERHAUL 25 MANUAL GEARBOX Standard and Torsen differentials 9 10 Fit final drive gear to ca
259. box Below auxiliary sockets Top of tank left side Behind switch panel Behind battery Rear electrical box 10 11 12 13 14 15 Front compartment right side Engine bay left side Under dash left side Inside lower spoiler Engine bay right side Behind light pod VN Lotus Service Notes SPLICE A BATTERY NU dane IGNITION UNFUSED CONN z 1 CHARG IGNITION FUSED CONN SED socket SPLICE B IGNITION SWITCH 5 N Ww G STARTER SWITCH SEE SHEET 8 rmn INSTR 21 8 O 6 RELAY CENTRE 3 ad ds SEE SHEET IMMOBILISER FUSEBOXB NY 5 A SHEET 9 SPLICE ALTERNATOR gura SPLICE N Ee STUDS REAR BULKHEAD BATTERY POSITIVE CRANK RELAY tear bulkhead STARTER SOLENIOD FUSEBOX use3 amp 4 ere RELAY STARTER MOTOR SPLICE sheet 1 Page 29 Lotus Service Notes SALIER D N ON UN D ON B FUSE 4 7 5 w 2225 2 21 FUSE 1 20 amp N FUEL INJECTOR RELAY FUEL PUMP AC C ERI ae ow FTHC 3 FTUA 1 BULK 1 Oo Y i eee SPLICE A FTHC 4 BULK 45 wee ee INJECTOR 1 IMMOBILISER INJECTOR 2 IMHC 6 BULK 5 gt lt 1 INERTIA SWITCH INJECTOR 3 02 SENSOR SEE SHEET 4 2 BU INJECTOR 4 z EI lt
260. bsolutely necessary 5 Make cylinder number reference mark on big end bearing caps NOTE Number stamped below cap joint is bearing bore size code Number stamped on connecting rod is cylinder number and letter is weight code 6 Remove 4 dowel bolts and 2 big end bearing caps from Numbers 2 and 3 connecting rods keep dowel bolts and caps in their fitted order Remove and discard big end bearing shells 7 Release connecting rods from the crankshaft carefully push pistons to top of their bores 8 Rotate crankshaft 180 9 Remove Numbers 1 and 4 big end caps remove and discard bearing shells Push pistons to top of their bores 10 Remove and discard 4 big end bearing shells from connecting rods OVERHAUL 81 ENGINE Crankshaft remove 1 Remove big end bearings caps and bearing shells 2 Remove pistons and cylinder liners 3 Using assistance position cylinder block cylinder head face downwards on a smooth clean wooden surface 6 1 2 1777 5 Remove beanng ladder 6 Remove and discard main bearing shells from bearing ladder 8RM 3485 4 Working in sequence shown slacken then remove 10 bolts securing bearing ladder NOTE 2 bolts A are under the flanges of the rear mounting brackets Also note position of flanged head longer bolt at front end of ladder 12 1778 7 Using assistance lift crankshaft from cylinder block 8 Remove and discard crankshaft rear oil s
261. by compacted old adhesive limiting the penetration of the fixing bolt If necessary use a small screwdriver or similar to ensure all adhesive is removed and dry the thread with a paper towel and airline When fully clean measure the depth of the threaded hole using a depth gauge or narrow steel rule Minimum depth 26 mm If the dimension is less than this figure replace the ball joint 2 Ifthe original M10x70 bolt is to be refitted thoroughly clean the bolt thread using a wire brush Degrease dry If a new bolt is to be fitted degrease and dry the bolt thread Fit the bolt through the flat washer lower wishbone bush and chassis 3 Apply Permabond A134 to the whole of the bolt thread from tip to shank Applying threadlock before insertion of the bolt may glue the bolt into the wishbone bush 4 Thread the bolt into the ball joint and torque tighten to 45 Nm only with the car at ride height Cars bui 479 Cars built from December 98 onwards use toe link ball joints with integral studs secured to the chassis and hub carrier with M10 Nyloc nuts The outboard end conical spacer differs from that used for the earlier type joints by featuring an internal chamfer to clear the stud root and by an increased height The shim washers also differ in being of larger diameter to fit above rather than below the conical spacer The integral stud type ball joint is the service replacement for the previous type joint and is
262. c control unit to camshaft carrier Withdraw hydraulic control unit remove seal plate Remove and discard 2 labyrinth seals and rack seal from seal plate CAUTION Take care not to damage labyrinth seal retaining lugs on seal plate 14 1801299 1 ee 7 qoo 5 12M3494 Fit camshaft gear to front VVC mechanism Screw tool 186 1299 and 186 1299A 1 into oil seal Remove VVC housing oil seal by tightening centre of tool discard oil seal Remove camshaft gear boit Repeat above procedures for rear VVC housing oil seal 12 3487 19 19 20 A Remove and discard 2 bolts securing each VVC housing to cylinder head Slacken 2 bolts securing each VVC housing to camshaft carrer by 1 turn CAUTION Do not exceed 1 turn 21 12M3488 Using sequence shown progressively slacken and noting the position of 4 longest bolts remove 32 bolts securing camshaft carrier to cylinder head OVERHAUL 39 ENGINE 22 22 eege 9 eg lg DTY WE pur A y 12 3489 24 CAUTION During the following operations it is essential to ensure that front and rear inlet camshafts are retained in their respective VVC assemblies if camshafts are removed from their VVC assemblies then complete assembly must be replaced it is not permissible to refit camshafts to VVC assemblies 22 Ensunng that f
263. camshaft and fit to new with its split towards centre of camshaft Remove all traces of Plastigage using an oily rag OVERHAUL 43 ENGINE Timing gears Non VVC engines 1 Clean timing gears check gear teeth for damage and drive pin slot for wear replace gears as necessary CAUTION If gears have been subjected to prolonged exposure to oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent 44 OVERHAUL Camshafts and timing gears K16 VVC engines inspection Camshafts NOTE Carry out camshaft inspection after N removal of valves 1 Clean camshaft carrier and cylinder head bearing surfaces use suitable solvent to remove sealant CAUTION Do not remove clamps 18G 1770 whilst cleaning or inspecting inlet camshafts 2 Inspect cams and bearing joumals for wear pitting and scoring replace components as necessary NOTE Inlet camshafts and VVC mechanisms will only be supplied as an assembly ENGINE Hesse Checking camshaft bearing clearance VVC engines 1 Position exhaust camshaft in cylinder head and place a strip of Plastigage across each camshaft joumal 18G1770 18G1770 1 X 4 12M3516A 2 Rotate front and rear VVC control sleeves until timing plates 18G 1770 1 front and 18G 1770 2 rear can be inserted through the housing and into the control sleeve slot CAUTION Do not remove clamps at this N s
264. camshafts do not N rotate OVERHAUL ENGINE Hesse 41 Restrain each timing gear in turn using tool 12M35 15 12 182 and tighten bolts to 65 Nm 45 Fit rear timing belt cover fit and tighten screws to 10 Nm 42 Temporarily fit front timing gears to their respective camshafts rotate gears until timing marks on all 4 gears are aligned facing inwards fit tool 18G 1570 43 Check alignment of each pair of timing marks in turn using a straight edge 44 Remove tool 18G 1570 and front timing gears OVERHAUL 69 ENGINE Cylinder head K8 and K16 Non VVC engines fitted with a distributor refit CAUTION If crankshaft has been rotated check that timing marks on crankshaft timing gear are aligned with flange on oil pump and that tool 186 1571 is locking flywheel 1 Check cylinder head bolts in oil rail See Cylinder head bolt inspection Renew bolts as necessary 2 Check that 2 locating ring dowels are fitted in Cylinder block CAUTION The type of ring dowel fitted must be maintained nylon ring dowel must not be used in place of a steel ring dowel 3 cylinder head bolts under head and threads 4 Remove cylinder liner retainer clamps 18G 1736 CAUTION Do not rotate crankshaft until AN cylinder head bolts are fitted 5 Fit new cylinder head gasket DRY with identification markings facing upwards on to cylinder block CAUTION Take care not to damage A sealing f
265. carrier is fitted 64 OVERHAUL 10 Remove clamps 18G 1770 CAUTION Do not remove timing plates at this stage or damage to VVC housing seals will result M124948 11 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on cylinder head as shown then spread to an even film using a roller CAUTION Ensure that sealant is kept clear of oi feed holes oil grooves and control shaft journals and that assembly is completed within 20 minutes During the following operations it is essential to ensure that front and rear inlet camshafts are retained in the camshaft carrier and their respective VVC assemblies Take great care not to rotate camshafts or control shaft 12 Invert camshatt carrier and fit to cylinder head ENGINE esee 12M3503 13 Fit 32 bolts noting that 4 longest bolts are fitted at each end of camshaft carrier 14 Using sequence shown progressively tighten bolts to 10 Nm 15 Remove timing plates 18G 1770 1 front and 18G 1770 2 rear 12M3504 17 16 Fit and tighten new bolts front and rear VVC housings to camshaft carrier to 10 Nm 17 Fit and tighten new bolts VVC housings to cylinder head to 10 Nm 18G 1769A Zi NOTE Camshaft front oil seal illustrated 18 Position oil seal protector 18G 1749 over end of camshaft and fit new exhaust camshaft front and rear oil seals using tool 18G 1769A NOTE Front oil seals are coloured LS BLACK rear
266. ce replacement ball joints are supplied only as integral stud type complete with associated spacers and shim washers Cars built prior to VIN W 5479 December These cars use female threaded ball joints and Permabond A134 thread locking compound for secondary bolt security A conical spacer and stack of shim washers is fitted between the outer ball joint and the hub carrier in order to provide for adjustment of the bump steer characteristic the specification for which is fully described in sub section XA 8 In order to optimise the thread engagement of the outer fixing bolt into the ball joint for various shim washer configurations two variations of bolt length are used and it is vital to follow the build procedure detailed below to ensure complete integrity of the joint If the toe link is released from the hub carrier note and retain the shim washer stack and conical spacer fitted between the ball joint and hub carrier and do not disturb the toe link length setting to avoid the necessity for a subsequent full geometry check If on disassembly the bolt is found to have been significantly below the assembly torque of 45 Nm such as to allow potential movement between the ball joint and hub carrier the bolt should be renewed see below for correct bolt length and the hub carrier hole and ball joint carefully inspected for wear or damage If a ball joint requires replacement the later type integral stud joint should be fitted together wit
267. competition it is recommended to disable the passive immobilisation by disconnecting the driver s door switch The alarm may still be armed on demand but will not be triggered by the driver s door If the car is equipped with the optional Cobra alarm system passive immobilisation can be overridden by unplugging the immobiliser module and substituting bridging plug 111 01235 Cobra immobiliser module SH Engine management ECM Anti tamper cover Page 6 e Lotus Service Notes Section XA 16 Unless a 20f p i radiator is already fitted replace the 16 f p i radiator with the later type Parts Required Radiator engine cooling 20 f p i A111K0021F Refer to sub section KF 4 for fitting details Note Engine Air Filter Maintenance Instruction The ITG foam air cleaner element supplied as part of this package requires the following maintenance procedure to ensure efficient results 1 The new filter element must be oiled before use see installation procedure 2 The filter must be cleaned regularly dependent on operating conditions Cleaning can be carried out using a bath of petrol or with liquid detergent and warm water Rinse in warm water after cleaning Do not use hot water After cleaning the filter should be allowed to dry thoroughly Do not use a high pressure air line or a hot air blower 3 After cleaning the filter must be re oiled Use the ITG dust retention aerosol to spray a good covering of
268. connect 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 Release the fixings along the front and rear edge and remove the shear panel which closes the chassis box section housing the fuel tank Note that this panel is a structural part of the chassis and that the car should not be used without the panel fitted Fuel tank Fuel tank bay shear panel Throttle amp gearchange cable clips Page 7 Lotus Service Notes Section LH 7 Support the tank before removing the four bolts securing the fixing brackets at the base of the tank to the chassis and carefully lower and remove the tank Captive fixing Tank rear fixing Captive fixing Tank front fixing 8 Retit the tank in reverse order to removal taking care to connect the fuel pipes to the correct spigots on the fuel pump assembly Feed spigot marked E rearmost Return spigot marked R foremost Note that the centre vent connector is not used and is blanked off internally Ensure that the shear panel is fitted beneath the fuel tank bay before driving the car LH 6 FUEL PUMP SENDER ASSEMBLY The combined fuel pump fuel
269. ct oil seal Place input and output shafts together and fit assembly in differential housing NOTE Position housing so that when fitted end of input shaft is clear of bench Remove tool 18G 1269A Ensure output shaft nut is staked Position gears in neutral Raise both shafts slightly and fit selector forks assembly ensuring forks are located in grooves in synchro sleeves Fit reverse idler gear thrust washer and shaft NOTE Large boss on idler gear must be towards dilferentiai housing Fit reverse selector fork and bracket Fit interlock assembly ensuring base of interlock locates in slot at lower end of 1st 2nd selector shaft Fit and tighten interlock retaining bolts MANUAL GEARBOX 0 0 32 Position gear case over differential housing keeping gear case square to housing 33 Lower gear case into position and at the same time expand output shaft bearing circlip using tool 18G 1392 34 Push gear case fully down on to differential housing 35 Ensure circlip is fully seated in groove in output shaft bearing raise output shaft and a click will be heard as circlip enters groove 36 Fit and progressively tighten gear case bolts to 45 Nm 37 Fit reverse idler shaft bolt and tighten to 67 Nm Use a new washer 38 Apply thread sealant to access plug fit and tighten plug using tool 18G 1472 39 Fit reverse light switch and new washer tighten to 25 Nm 40 Fit speedometer drive pinion and hou
270. ctivated surface and the adhesive compound Supplied in 250 ml aluminium con tainer with RED coloured cap 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 Page 7 E Lotus Service Notes Section BM Notes 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 24 hours re activate by applying a further coat of Betaprime 5404 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 Application Notes Adhesion promotor used to maximise the performance of
271. ctive washer The rear end of the shaft is secured by a circlip which retains the bearings in the gear case Synchromesh is by spring rings and spline extensions in the inner faces of the synchromesh sleeves Gear selection is via an interlock and gearshift holder assembly which transmits movement of the main selector shaft to the selector forks Later specification gearboxes employ a reverse brake mechanism Lubrication is by splash An oil gutter located on the upper side of the gear case collects splashed oil and directs it to oil guide plates which distribute it to the hollow input and output shafts DESCRIPTION TORSEN DIFFERENTIAL Gearboxes fitted to certain models incorporate a Torsen limited slip differential The word Torsen is derived from torque sensing which describes the principle of operation Two types of differential are fitted type A is fitted to gearboxes having serial number prefixes KABX and K7BSUT Type B is fitted to gearboxes having serial number prefixes C6F TUT WADTUT CeDTUT and C6DTUTH The assembly comprises a final drive gear bolted to the differential casing two helical gears splined to the drive shafts and three pairs of element gear assemblies arranged at 120 intervals within the differential casing and running at right angles to the helical gears Each of the element gear assemblies comprises a worm gear and two spur gears running on a journal pin The worm gears are in constan
272. cylinder Withdraw the piston and spring and remove the rubber seal from the piston taking note of the orientation Clean all parts thoroughly with only new brake fluid and dry with a lint free cloth Carefully examine the cylinder bore for scoring corrosion or visible wear and replace if any such signs are apparent If the cylinder is serviceable rebuild the unit using new seals and components from the appropriate overhaul kit Bleed nipple Piston Slave cylinder Pushrod body Clevis pin On reassembly scrupulous cleanliness is essential Clean hands thoroughly beforehand Lubricate the seal the cylinder bore and internal components with clean brake fluid Fit the seal into its groove on the piston with the lip towards the closed end of the cylinder Insert the spring and piston assembly into the cylinder taking care no to bend back the seal lips Pack the inside of the dust boot with rubber grease and seat the lip of the boot in the groove on the outside of the cylinder body Fit the pushrod throught the dust boot and press the piston against its spring several times to check for free movement of the piston Refit the cylinder as detailed above Piston seal Dust boot Hydraulic Pipe The one piece flexible synthetic pipe between master and slave cylinders is routed through the dash baffle panel and along the outside of the left hand chassis sideframe enclosed within the composite sill panel and wrapped with
273. cylinder head Retain tappets in fitted order and invert to prevent oil loss NOTE Dowel located 37 _ENGINE Camshaft carrier and camshafts K16 VVC engines remove 12 3481 1 Remove 4 bolts securing camshaft rear cover remove cover 12M3482A 2 Using tool 12 182 rotate inlet camshaft rear timing gear until timing marks on both rear gears are facing outwards NOTE With timing marks in this position the lobes of numbers 3 4 5 and 6 cams on the inlet camshafts should be facing upwards 3 Suitably identify each rear camshaft gear to its respective camshaft 5 12 182 12M3483A 7 4 4 Using tool 12 182 restrain rear inlet camshaft timing gear and remove bolt and washer retaining gear 5 Repeat above procedure for exhaust camshaft rear timing gear 6 Remove tool 12 182 from gear 7 Remove both rear timing gears from camshafts remove and discard rear timing belt CAUTION Rear timing belt must always be replaced during engine overhaul Do not rotate crankshaft with front timing belt removed and cylinder head fitted 12 3485 8 8 Remove bolts securing camshaft rear timing belt backplate 9 Remove rear timing belt backplate 38 OVERHAUL 10 11 12 13 14 15 16 17 18 12M3486A Remove temperature transmitter from hydraulic control unit remove and discard sealing washer Remove 3 bolts securing hydrauli
274. d Lotus Service Notes Introduction The Vehicle Identification Number V I N is stamped on the chassis in the right hand rear wheelarch area and is also printed on a label stuck to the body in the front services compartment The engine number is marked on a vertical patch at the left hand end of the forward face of the cylinder block and is most easily viewed using a mirror Both numbers should always be quoted with any vehicle enquiries as Factory records are filed against and specification change points are identified by VIN or engine number The vehicle licence number may not accurately reflect vehicle age may also be changed during the car s life and is an unreliable method of vehicle identification VIN ON CHASSIS comprises 17 characters coded in accordance with European Economic Community EEC directives Note that the coding of the V I N changed with the introduction of 98 Prior to July 2000 change points will be identified in Service Notes and Service Parts Lists by characters 10 modei year and 15 17 or 14 17 serial number After July 2000 characters 10 to 17 will be quoted 96 97 Model Year Emission Engine Type YN1 1 8 K16 Model O Elise Model Year T 21996 21997 Chassis Body A RHD F LHD Vehicle Type 111 Elise Number SE 2000 04 NO NN NEN 7375
275. d d COIL PACK SEE SHEET 8 BULK 15 INSTR 3 A sheet 2 Page 30 Lotus Service Notes N WN UN gt ON D FUSE A1 REAR FOG SHEET 15 SPLICES SIDE LIGHT RELAY IMMOBILISER 10 N SEE SHEET 8INSTR2 FUSE B3 7 5 amp FUSE 12 COOLING FAN COOLING _ _ E m COOLING BULK 4 25 Se Dek Ee Be COOLING FAN 1 1 SPLICE D G l A EEEE E CANNISTER m NU PURGE BUTTERFLY J BUTTERFLY 3 SEE SHEET 8 SOLENOID SOLENOID A SOLENOID x ios ON us SHEET SEE SHEET 4 4 SPLICE G SPLICE E BULK 8 QBULK 66 BULK 7 RPM OROP SWITCH NOTE NOT FITTED TO STANDARD 340R Lotus Service Notes SAT gt N UN U L mu wem 3amp 0802 diagnostic connector SPLICE BAROMETRIC A B THROTTLE POSITION SPLICEB BULK 21 BULK 19 BULK 42 BULK 22 BULK 20 BULK 3 BULK 2 wW 8 47K ohms 97 88 73 79 11 9 37 86 36 35 39 NOTE RESISTOR 15 APPROXIMATELY Samm K FROM ECU CONNECTOR E C M 67 LK 38 a SEE SHEET 3 02 SENSOR BULK 17 BULK 10 BULK 31 SPLICE G d SIG SPLICE M 5 et 4 PWR a Sa ET Page 32 a Lotus Service Notes 340R SEE SHEET 1 WIPER MOTOR DELAY UNIT SCREENWASH PUMP Page 33
276. d aluminium bracket is bolted to the bottom of the hub carrier utilising two of the lower ball joint plinth fixings The pivot boit uses a sliding sleeve in the lower leg of the bracket to avoid any bending stress in the bracket when the bolt is tightened Note that each side of each of the Uniball joints must be faced by the smaller end of a conical washer in order to allow full articulation of the joint A stack of six shim washers is provided at the outboard end of the link to be distributed above and below the Uniball in order to adjust the joint height and attain the desired bump steer characteristic The default setting of the stack is for one washer above the joint and five below but for fine tuning of the toe curve refer to Service Notes sub section XA 8 Support bracket toe link to chassis Uniball toe link Conical spacer washers Shim washers bump steer Mounting bracket E E Uniball link to hub adjust i carrier sg Uniball 1999 n1 page ae Lotus Service Notes Section XA XA 8 ROAD SPRING amp DAMPER SET A111C0138 Road springs and dampers are available as a vehicle set designed to be used with a lowered ride height for track use The front springs are uprated from 27 5 N mm to dual rate 25 40 N mm springs and the rears are uprated from 40 to 50 N mm All four fixed calibration Koni dampers are both stiffer and shorter and feature different bump stops and adjustable spring platforms witho
277. d from front of camshaft carrier not visible repeat the foregoing procedure as necessary NOTE Timing slots in both VVC control A steeves should now be visible 27 Push hydraulic control unit piston to top of bore 28 Fit hydraulic control unit fit and lightly tighten 3 bolts 12M3509A 30 Apply low pressure air to oil temperature transmitter port in hydraulic control unit to extend rack 31 Check that rack is fully extended i e rack teeth are at limit of travel and timing slots are no longer visible through holes in camshaft carrier 32 Tighten hydraulic control unit bofts to 25 Nm ovERHAUL 67 ENGINE 33 Fit anew sealing washer to oil temperature 34 Fit oil temperature transmitter and tighten to 15 35 Thoroughly clean rear timing gears 68 12M35 10 transmitter Nm M12 3512 36 Fit rear inlet camshaft timing gear fit but do not tighten bolt 37 Fit exhaust camshaft rear timing gear fit but do not tighten bolt 38 Using tool 12 182 rotate both timing gears until timing marks on gears are facing outwards 39 Check alignment of timing marks using a straight edge NOTE With timing marks in this position the lobes of numbers 3 4 5 and 6 inlet cams will be facing upwards 40 Remove bolt and withdraw rear inlet camshaft gear sufficiently to enable a new rear timing belt to be fitted fit rear timing belt refit bolt and washer CAUTION Ensure that
278. d 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 Ib in when the tyres are warmed to normal running temperature The tyre valve dust 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 Wheel amp Tyre Specification Wheels Type std prior April 99 AWI light alloy 5 split spoke style Approx VIN X 6429 std from April 99 Rimstock light alloy 12 spoke style 1115 amp std option 0 2 light alloy 6 spoke style Size front 5 5J x 15CH H2 14 rear std 7J x 16H2 ET16 1115 amp std option 7 5 x 16H2 ET10 PCD 95 25 mm Inset front 14 mm rear std 16 mm 111 amp std option 10 mm Wheel nut torque 80 85 Nm Radial run out at bead seat 0 3 mm max Lateral run out at rim flange 0 3 mm max 340
279. d of the boot and the joint and fitting the retaining clips Tighten the clips using suitable pliers Refit the driveshaft assemblies to the car see above 5 TRANSMISSION REPLACEMENT With the car supported on a wheel free lift the transmission can be removed from below leaving the engine in situ 1 Remove the LH rear lower wishbone Release the bolt securing the spring damper unit to the lower wishbone Release the wishbone to chassis pivot bolts Release the parking brake cable clip and swing the wishbone out of the way Release the RH rear suspension toe control link from the hub carrier and release the top ball joint plinth from the hub carrier taking note of the camber adjustment shimplates in order to allow withdrawal of the driveshaft from the transmission Release both driveshaft inboard C V joints from the transmission using special wedge tool TO00T 1276 or by applying a shock pull to the C V joint body using a slide hammer with a forked end Fit blanking plug T000T 1385 into the transmission to limit the amount of transmission oil loss CAUTION Do NOT attempt to remove an inboard C V joint from the transmission by pulling on the driveshaft This action will cause the joint to become disassembled and may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive ax
280. de towards the centre Folding roof fabric 5 Release the two roof bows from the side rails and stow in their locations behind the seats 6 Remove each siderail by pushing forwards whilst pulling the rear end outwards to release from the rear end retaining clip Withdraw the rail front end spigot from the windscreen pillar Stowage of roof bows Removal of side rail 00548 7 Lay the two siderails on the roof fabric and roll up the roof with the siderails inside Place the roof the storage bag if available and stow either behind the seats or in the rear luggage compartment Important Note f 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 The roof may be treated periodically with Fabsil silicone waterproofer A111B6061 especially on the cant rail flaps and seams in accordance with the manufacturer s directions BN 2 FRONT BONNET Bonnet release The front bonnet is a composite mould handle ing which incorporates outlet ducts for the engine cooling radiator with a reinforcing rib bonded to the underside of the panel The bonnet uses a single hinge at the front edge and a cable release latch at the rear end with the release handle located in the top of the driver s footwell Note that the handle is pulled downwards to release the bonnet The
281. dio set are tied back to the fascia harness An ISO size hole is provided in the dash requiring only that the moulded plastic finisher is replaced with a two part version see sub section BN 12 The audio power supply is switched with ignition Velcro Speaker Panels Speaker wiring terminates in the vicinity of each cabin rear corner fin isher speaker panel To remove a panel release the seat belt reel remove the screw at the outboard top corner of the panel and at the inboard edge also anchors the luggage net and pull the panel away from its Velcro fastening The specified speakers are Alpine APE 1620 6 165 mm co axial 2 way nominal 30W peak power 90W 4 ohms impedance The speaker panels need to be fettled to accommodate the se lected speakers Stowage net hook Speaker Speaker grille Seat belt real bolt Velcro Roll bar seat belt bracket Transformer Aerial Heat protective The maintenance free trans sleeving former type flexible aerial is mounted on the engine cover and features an antenna mast which may by unscrewed by hand from its base if necessary to guard against vandalism All cars are fitted with an aerial co axial lead routed between the radio plug and the LH front corner of the engine bay from which point an aerial extension lead is required to connect with the aerial The aerial amplifier lead is built into the main har ness and is tied back at the corner of the engine bay T
282. dipstick tube bracket fit and tighten bolt to 10 Nm 7 Connect coolant rail to thermostat cover 8 Align coolant rail to cylinder block fit and tighten bolts to 25 Nm 20 OVERHAUL FLYWHEEL AND STARTER RING GEAR Flywheel remove 1861674 124937 1 Fit flywheel locking tool Flywheel without reluctor ring use 18G 1571 Flywheel with reluctor ring use 18G 1674 CAUTION Ensure tool engages teeth on flywheel not the reluctor ring N ENGINE IN NOTE Flywheel without reluctor ring illustrated 8AM 3477 2 Remove and discard 6 bolts securing flywheel 3 Using assistance remove flywheel from crankshaft NOTE Dowel tocated OVERHAUL 21 ENGINE Starter ring gear remove 44 12 1936 Remove flywheel Drill a 3 mm diameter hole at root of 2 teeth Apply a cold chisel to root of teeth break ring gear and remove from flywheel WARNING Suitable eye protection must be worn Starter ring gear refit 1 Heat ring gear evenly to 350 C indicated by light BLUE colour Locate ring gear on flywheel and press hard against flange WARNING Handle hot ring gear with care 2 Allow ring gear to air cool 3 Fit flywheel i SE 22 OVERHAUL Flywheel refit CAUTION Flywheels fitted to VVC engines have reluctor ring with 4 teeth at unequally spaced intervals missing whilst flywh
283. discard O ring 14 Release hamess from clip M12 7256 NOTE Camshaft cover fitted to early ZEN engines illustrated 6 Remove 2 screws securing spark plug cover 7 Remove spark plug cover 8 Disconnect 4 plug tubes from spark plugs 9 Remove any debris from spark plug recesses 10 Remove and discard 4 spark plugs 11 Release HT leads from camshaft rear belt COVer re eee gL ALE A SDE ENS PU GI CREP IA ASIEN SE APE APSA SA EBL ET Ru MER RELIED SES ESTED ETE ID CE EEL ETA GREECE ERES SLO PLO OVERHAUL ENGINE All engines NOTE Camshaft cover fitted to early engines illustrated 15 Progressively slacken then remove 15 bolts securing camshaft cover 16 Remove camshaft cover remove and discard gasket 17 Check and record crankshaft end float 18 Using sequence shown progressively slacken then remove 10 cylinder head to oil rail bolts 19 Remove bolts and store in fitted order CAUTION Removal of cylinder head bolts results in a tightening up of crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G 1736 are fitted 20 Using assistance remove cylinder head assembly CAUTION Cylinder head is dowel located do not tap it sideways to free it from cylinder block Place cylinder head on blocks of wood to prevent damaging valves 21 Remove and discard cylinder head gasket 1291770 22
284. dle assembly to the door and unclip the control rod end clip to enable the rod to be unhooked from the handle After refitting ensure that the control rod is fitted into the two rod guide clips Door shell Release handle Rod guide clips 2254 20 To replace the 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 secur ing 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 Control rod access Viewed from outside Plate bonded inside door shell Control rod to relay lever wi Outboard To replace the relay lever components The relay lever components comprise a shaft with an integral lever on one end which connects to the exterior lock button and a second lever pinned to the other end which connects to the latch mechanism The shaft is supported in two fibre bushes housed in the bracket connecting the rear end of the door beam to the door shell Lotus Service Notes Section BN Rod to interior handle To replace the latch mechanism Remove the door trim panel Unclip the cap from the window winder handle release CS the retaining screw and withdraw the handle Release the seven fixing screws and remove the door trim panel Unclip the control
285. dy colour All cars have gold painted grilles as follows radiator air intake radiator outlet engine lid outlet rear clamshell recess engine bay intake All cars have gold painted 111S type road wheels black and gold Alcantara steering wheel gold painted dash insert panels 111S type black leather seats with gold Alcantara centres gold decals on rear body and dash black amp gold nose badge Union Flag decal on rear Standard versions also have headlamp covers and rear wheelarch spats Elise Type 49 October 99 Available based on either standard or 111S versions Two tone red white body colour All cars have gold painted 1115 type road wheels black and red Alcantara steering wheel 1115 type black leather seats with red Alcantara centres gold decals Standard versions also have headlamp covers and rear wheelarch spats Elise Millenium October 99 Available based on either standard or 111S versions Atlantis Blue body colour Ail cars have blue Alcantara steering wheel pad and sill trim panels 1115 type black leather seats with blue Alcantara centres Standard versions also have 111S type road wheels rear wheelarch spats and headlamp covers Cars were usually supplied with a range of dealer fitted Lotus accessories Forged Steel Rear Hub Carriers November 99 VIN X 8177 approx New design forged steel rear hub carrier replaces extruded alloy carrier and incorporates caliper mount ing plate and lower ball joint carrier El
286. e Red harness tag re circ Blue harness tag footwell Screen flap solenoid To screen flap actuator CN Vacuum supply to To footwell E 4 solenoid centre spigots flap actuator SC flap actuator water valve Inlet port to engine Vacuum reservoir Outlet port to solenoid valves ith R rw h liner removed 2000 04 E Lotus Service Notes Section PH Distribution Control Details The distribution control is an electrical selector switch with one input terminal and using 3 output termi nals Switch functionality is as follows FUJISOKU Switch terminal Cable colour Function Fed at switch position ignition supply All L Green amp Black Footwell flap Footwell M Green amp Purple Footwell amp sceen flaps Footwell amp Screen H Green amp Orange Screen flap Screen Note that diodes in the green purple circuit isolate the footwell and screen flap actuator circuits from each other at control positions other than footwell screen EES Ee EE EE EE UA EIS IE I EE EE PE E mma e ee NSE EE EE 2000 04 dnm E Lotus Service Notes Section 4 H OLIN L A C Control When the a c request button on the fascia is pressed the signal is routed through the evaporator thermo static switch to ensure no icing and the trinary switch to check acceptable refrigerant pressure before feed ing the ECM i
287. e Consequently only option 3 above is suitable for road use Competition Harness Shoulder amp crutch Strap Detail Belt looped back through buckle this threading also applies to crutch strap Roll bar A frame tube Buckle Page 8 a Lotus Service Notes Section XA COMPETITION SEAT Pana Ta Lotus Service Notes Section XA COMPETITION STYLE SEAT Special stud Page 10 Lotus Service Notes Section XA 4 ROLL OVER BAR COMPETITION REINFORCEMENT KIT This kit is designed to provide additional bracing to the roll over bar for competition use and allow the fitment of the 6 point competition seat belt harness see sub section XA 2 The standard 3 point inertia reel seat belts cannot be used with this kit Note that the roll bar fairing and audio speaker panels must be removed or modified and that some drilling of the chassis is required to fit the forward bracing strut Description Roll Over Bar Competition Reinforcement Kit LHD Roll Over Bar Competition Reinforcement Kit RHD Comprising Frame roll over bar reinforcing Bolt 7 16 UNF x 25 frame to roll bar base Washer 7 16 End Spigot harness bar to roll bar Bolt M10 x 75 end spigot to roll bar Washer M10 Bolt M8 x 50 harness bar and bracing bar to end spigots Washer M8 S Nut 8 Bracing Strut roll bar to footwell U End Spigot brace to roll bar RHD LHD Bolt M12 x 80
288. e Continue with operation 7 10 Refit the belt guards Clutch Kit The clutch kit is a direct replacement for the standard components See Service Notes section QF B Rear diffuser panel Remove the rear diffuser panel and replace with the new standard Elise panel using new mounting struts which attach to pre drilled holes in the subframe top rear flange Carbon fibre headlamp blanking panels Remove the headlamp and turn indicator lamps and cut the lamp 2000 02 pagent S Lotus Service Notes Section XA housings from the topshell with a windscreen removal pneumatic knife Fit the headlamp blanking panels to the topshell using elastomeric adhesive Polycarbonate windscreen Remove the windscreen and replace with the lightweight polycarbonate version Refer to Service Notes sub section BN 13 Remove Complete wiper mechanism including washer components Rear shroud panel mid spoiler complete with rear fog lamp reverse lamp harnesses grilles and brack ets All four mudguards and mounting brackets Fit camber shim plates supplied to compensate for mounting bracket thickness Engine bay rear wall Driving lamps and mounting brackets Horn Front licence plate mounting and brackets Front air intake grille and towing eye Tyreweld canister and mounting clip Rear window Exterior mirrors and alloy spacers plinths Fit blanking grommets in topshell holes Side repeater lamp plinths Bond repeater lamps to body with el
289. e as selected from table DO NOT FIT UNDERSIZE BEARINGS Main bearings type table 1 2 3 4 5 Block Plain Grooved Grooved Grooved Plain Ladder Plain Plain Plain Plain Plain OVERHAUL 85 ENGINE Big end bearings selection GH zb I 7 BRM 3490 mm 1 Record big end journal code letters from crankshaft rear web 1 8 litre First letter is Number 1 big end bearing Big end journal tolerance Record big end bearing bore code numbers Grade A 48 000 to 48 007 mm this will be 5 6 or 7 located on the connecting Grade B 47 993 to 48 000 mm rod bearing cap Grade C 47 986 to 47 993 mm 2 Check crankshaft big end joumal diameters Clearance in bearings 0 021 to 0 049 mm 1 1 1 4 and 1 6 litre Maximum out of round 0 010 mm Big end journal tolerance Big end connecting rod end float 0 10 to 0 25 Grade A 43 000 to 43 007 mm mm Grade B 42 993 to 43 000 mm Grade C 42 986 to 42 993 mm 3 Select the appropriate big end bearing shells Clearance in bearings 0 021 to 0 049 mm from the table Maximum out of round 0 010 mm 4 Replace crankshatt if outside tolerance Big end connecting rod end float 0 10 to 0 25 Big end bearings size selection table Big end bore Crankshaft big end journals BLUE BLUE RED BLUE RED RED BLUE YELLOW BLUE BLUE RED BLUE YELLOW YELLOW BLUE YELLOW BLUE BLUE Colour code on edge of bearing Thickness progression YELLOW Thin BLUE intermediate RED
290. e ball joint to steering arm nut to 30 Nm and set the front wheel alignment as detailed in sub section CG 2 Steering Rack Gaiters The convoluted gaiters sealing each end of the steering rack housing to the track rods should be in spected 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 Page 8 Lotus Service Notes Section HE 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 HE 6 RACK amp 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 8 lower fixing bolt to secure the housing to the vertical rear face of the crossmember A steel reinforcement channel is bonded to the outide 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 replace ment of the track rod ends and rack housing ga
291. e between piston and left hand side of cylinder liner viewed from front of cylinder block 4 Repeat above procedure for remaining pistons 3 Ensure rings are free to rotate position compression ring gaps A and B at 120 to each other and away from thrust side left hand side of piston when viewed from front Position oil control ring gap C and spring gap D at 30 on opposite side of gudgeon pin axis Clearance in cylinder liner bore K8 and K16 1 1 and 1 4 0 015 to 0 045 mm K16 1 6 and 1 8 0 01 to 0 04 mm NOTE Pistons and connecting rods are A only supplied as an assembly 94 OVERHAUL ENGINE asss Cylinder liners inspection 12M1786 1 Measure wear and taper in two axes 65 mm from top of cylinder liner bore 1 1 and 1 4 RED grade A 74 970 to 74 985 mm BLUE grade B 74 986 to 75 000 mm 1 6 and 1 8 RED grade A 80 000 to 80 015 mm BLUE grade B 80 016 to 80 030 mm Service liners are grade A and B Cylinder liner grade A or B together with the appropriate colour code will be found marked on outside diameter of liner CAUTION Cylinder liners with excessively glazed worn scratched or scored bores must be replaced do not attempt to hone or remove glazing from bore Later 1 8 engines only QKN 15 99 V Z 2 12 5823 e Cylinder liner bore grade e VIZ Cylinder liner step height NOTE Cylinder liners fitted to later 1 8
292. e blade is tapped to take the two M6 pivot screws which use plastic pivot bushes and steel thrust washers to connect the blade to the hinge bracket lugs For access to the hinge pivot screws it is necessary to remove the rear clamshell Page 6 eS Lotus Service Notes Section BN 4 FRONT CLAMSHELL The front clamshell is a one piece composite body moulding incorporating both front wings the front bonnet aperture radiator air intake and headlamp housings The clamshell is secured to the chassis and other body panels via threaded fasteners for ease of removal and to facilitate service access and body repair To Remove Front Clamshell 1 Remove both front roadwheels 2 Remove the front wheelarch liners From within the front services compartment release the fusebox from the passenger side wheelarch liner 3 fixings Remove the three screws at the lower rear edge and the two screws at the lower front edge of each liner Withdraw both wheelarch liners Edging strip Wheelarch liner fixing screws 5236 3 Remove the two 8 fixings securing the lower rear edge of the clamshell to the top of the sill 4 Remove the single M8 screw securing each top rear corner of the clamshell to a bracket at the top of the post 5 Remove the four fixings in the bonnet gutter one at each rear end and one in each front corner The rear pair are also used as adjustable mounts for the bonnet closing buffers and use
293. e buzzer Disarm the alarm before the 30 seconds elapses or the siren will be activated If adjustment is required refer to page 6 If the alarm system does not operate as described refer to the Trouble Shooting guide below Page 33 E Lotus Service Notes Section MN Alarm Trouble Shooting Symptom Vehicle was left for a few minutes without setting the alarm and now the engine won t start Possible cause Passive immobilisation has taken effect indicated by the tell tale flashing as designed see above Symptom The transmitter key will not arm or disarm system Possible cause Transmitter key battery low When the key battery becomes low the transmitter key L E D will blink in an irregular manner or once only instead of remaining lit until the button is released To replace transmitter battery a Open the transmitter key body by levering in the zone marked OPEN and withdraw the battery b The keys are powered by a 3v long life lithium battery type CR2032 With normal use this should last between 3 and 5 years After opening the new battery packaging touch only the sides of the battery and fit the battery into the key case with the positive side upwards as shown C Pressthe battery case together Transmitter casing Symptom Both transmitters fail to operate with good batteries Possible cause Transmitter programming has been inadvertently wiped during use of touch id repro gramme keys see above
294. e crankshaft clockwise 2 complete revolutions and align camshaft gear timing marks CAUTION Do not use camshaft gears gear retaining bolts or timing belt to rotate crankshaft 19 Slacken tensioner backplate screw and check that belt is being tensioned by the tensioner spring 20 Tighten tensioner backplate screw to 10 Nm and tensioner pulley Allen screw to 45 Nm OVERHAUL 9 ENGINE VVC engines Camshaft timing belt automatic tensioner remove 21 Disconnect tensioner spring from pillar bolt release spring from tensioner remove and CAUTION Timing belts fitted to engines discard spring with automatic timing belt tensioners are 22 Remove and discard pillar bolt not interchangeable with those fitted to engines with manual tensioners All engines 23 Ensure inserts are fitted in timing belt front upper cover 24 Fit timing belt upper front cover ensuring correct position of seals tighten screws and bottom bolt to 5 Nm 1 Slacken but do not remove bolt securing bottom of timing belt upper front cover NOTE Remove bolt when cover is not Ze slotted 2 Noting fitted position of longest screw remove 5 screws securing timing belt upper front cover 3 Remove timing belt upper front cover together with seal 10 OVERHAUL ENGINE Besse 18 1570 124952 4 Rotate crankshaft clockwise to align camshaft gear timing marks 90 BTDC CAUTION Do not use camshaft gears gear r
295. e filters and intake ducting Exhaust System The 340R engine uses a special exhaust manifold fabricated from 45mm steel tube leading via a short flexible section to the standard catalytic converter and then into a new transverse stainless steel muffler with twin high level outlets The muffler is wrapped in carbon fibre faced insulation to provide heat protection Starting Procedure The fuel injection and engine management system controls fuel delivery and engine settings under normal operating conditions i If necessary mobilise the engine by pressing the ignition key head transmitter button see Vehicle Secu rity Alarm ii Insert the ignition key into the switch steering lock and turn to position I to switch on the ignition note that position IIl is not operative iii Press the accelerator pedal to one quarter travel approx 25mm and press the starter button in the centre of the fascia As soon as the engine starts release the button and adjust the accelerator position to maintain 2 000 rpm for 10 seconds to minimise emissions If the engine fails to start within 15 seconds stop cranking and pause for 10 seconds before a second attempt ff difficulties are encountered press the accelerator half way down and repeat v Ifthe engine still fails to start it is likely that it will have become fuel flooded Provision is made to cut off the fuel supply completely when cranking by fully depressing the accel
296. e fitted to the lightweight flywheel on the new engine New longer fuel feed and return pipes are needed to allow fitment of the new airbox Parts Required included in fitting kit Fuel Feed Pipe A111L6039S 1 Fuel Return Hose A111L6040S 1 Clip fuel pipe support tie wrap A082W6324F 2 Clip fuel pipe support C clip A082W6587F 2 Oetiker Clip fuel return hose BO82K6060F 1 Fit the new fuel feed pipe to the left hand end of the fuel rail smearing the ring with silicone grease and tightening the two fixing screws to 4 Nm Fit the return hose to the RH end of the rail and secure with the Oetiker clip Secure the hose using the two wrap clips to the header tank water hose as shown Header tank water hose RE depan ny Ke V Mi r Fuel pipe clips Remove the charcoal canister from the LH front of the engine bay and re route the breather pipe from the roll over valve to vent to atmosphere at the RH engine mounting bracket Fuel return pipe Roll over valve Re routed breather hose Vented to atmosphere 427 Page 3 Kon Lotus Service Notes Section XA Lotus Service Notes Section Fuel filter 5 The mounting plate for the original air cleaner and fuel filter must be cut down to allow the new air intake trunking to be fitted 6 new carbon fibre airbox draws cold air from the LH air intake
297. e instructions When matching is complete it is then necessary to select CALIBRATION ID from the PROG menu to complete the operation Unless this is performed the engine will not run Note that for standard cars ECM matching can only be carried out using the 5AS card and security password system refer to service notes sub section MN 2 This programme is more comprehensive than the Pre Test and takes about 10 minutes to complete tests on many of the engine management components During this routine the scanner display will ask a series of questions and issue instructions to guide the operator through the test some parts of which require that the engine be run up to normal operating temperature The test should be used any time that a driveability concern is reported or if the Pre Test does not identify the problem Components tested in this routine include Coolant temperature sensor Fuel injectors Fuel pump Oxygen sensor heater relay Purge valve solenoid VCC control solenoids note that it is not normally possible to hear these solenoids operate Throttle position sensor Cooling fan Tachometer Idle air control motor Oxygen sensor The test results should be printed out to identify any detected faults If a fault is recorded note that problem may be in the component or the associated circuitry Refer to the appropriate EMN sub section or circuit diagram to diagnose the fault Displayi
298. e pipe connected to the supply connection on the pump assembly top plate From here fuel is piped to the fuel rail on the engine from which it returns to the inlet connection on the top plate and spills into the canister to supplement the primary pump output and keep the canister fully filled An umbrella valve in the bottom of the canister allows fuel to flow into the canister whenever the tank level is higher than the canister level This feature also permits a continued fuel supply to the secondary pump stage in the event of a blocked primary stainer For further details of the fuel pump filter and tank refer to section LH 2000 01 E Lotus Service Notes Section EMN Filler breather hose Fuel filler neck Fuel filter Fuel pressure regulator valve Fuel tank Fuel pump Fuel rail Fuel injector Fuel feed line Fuel return line 27208 The fuel pump is controlled by the the fuel pump relay located in the relay module and is energised under the following conditions When the ignition is first switched on the ECM grounds the pump relay coil for few seconds order to pressurise the fuel rail and then switches off When cranking the ECM receives an engine speed signal and operates the pump continuously When the engine is running the ECM receives an engine speed signal and operates the pump continu ously If the engine stalls the ECM will switch off the pump after about 10 seco
299. e port Screen Avacuum actuator mounted externally on the passenger side of the plenum is connected via two rods and a bellcrank lever to a screen flap which controls airflow into the demist duct to which the plenum is mated The default position of the flap is to open the demist duct with vacuum required to close the port The plenum is a bonded assembly which is not dismantlable Service is only by replacement of the complete assembly Footwell flap actuator Outlet trunking inside plenum to face level vents Screen flap Outlet to actuator demist duct Bellcrank lever Footwell flap Screen flap Air inlet from blower fan 000 04 SE 47 Lotus Lotus Service Notes Section PH Air Distribution Airflow The distribution control knob provides four set tings as follows Face Level Turned fully counterclockwise all the airflow is directed to the four face level vents each of which may be individually adjusted via a volume con trol thumbwheel and direction control knob No solenoids are energised When engine vacuum is generated the screen flap closes Footwell At this position air is supplied to the footwell vents and to the face level vents For maximum footwell ventilation close off the face level vents via their individual thumbwheels Footwell solenoid energised vacuum opens footwell flap Footwell amp Screen At this position air is supplied to the windscreen footwell
300. e remaining bolts 30 OVERHAUL ENGINE K sse 27 186 1570 2 482 Cl 2 22 Remove camshaft locking tool 186 1570 23 Using tool 12 182 rotate inlet and exhaust camshafts clockwise until reluctor rings clear bolt heads 7 and 8 24 Progressively slacken cylinder head bolts 7 to 10 25 Remove 10 cylinder head bolts and store in titted order CAUTION Removal of cylinder head bolts results in a tightening up of crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G 1736 are fitted 26 Suitably identity each camshaft gear to its respective camshaft and using tool 12 182 to hold camshaft gear against rotation remove bolt and plain washer from each camshaft gear 27 Remove camshaft gears M124969 NOTE Timing belt rear cover fitted to engine with 5 bolt front engine mounting illustrated 28 Remove screw securing rear of timing belt rear cover to coolant pump NOTE This is the longest of the rear cover securing screws 29 Remove screws securing timing beft rear cover remove cover 30 Remove timing belt tensioner pillar bolt 31 Using assistance remove cylinder head assembly from cylinder block CAUTION Cylinder head is located do not tap it sideways to free it from cylinder block Place cylinder head assembly on blocks of wood to prevent damaging valves 32
301. e the fuel system pressure before servicing the fuel rail or any related component See Fuel Pressure Relief Procedure below ii 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 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 except the unpressurised return line Pull out the fuel pump fuse to rear of engine management ECM at LH side of rear luggage compart ment start the engine and run until it stops from starvation Crank the engine for a further 10 seconds If the engine is a non runner pull out the fuel pump fuse and crank the engine for a total time of 60 seconds to minimise residual fuel pressure Disconnect the battery Use a shop towel to absorb the small amount of pressurised fuel remaining as a fuel feed pipe connection is released Fuel pump and dispose of safely fuse 10A LH 4 FUEL FILTER The fuel filter is fitted in the feed line between pump and injector rail and protects the delicate injectors from dirt particles and debris not screened out by the pump inlet strainers The paper element fuel filter is contained within a steel canister fitted with compression joints and is mounted in a holder on t
302. e wheel leans inwards at the top positive when leaning outwards Camber angle Vertical Wheel centreline a 1998 02 Lotus Service Notes Section DE 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 Top wishbone Camber adjustment a Ball joint plinth Camber adjustment shim plates are fitted between the top wishbone ball joint plinth and the hub carrier Shims are available in 1 mm thickness 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 Before final assembly coat the joint face between the steel shim plate and the alloy hub carrier with Duralac MSDS anti corrosive jointing compound A111C6017 and assemble whilst the compound is still tacky Apply Permabond A131 912 7034 to the threads of the two ball joint plinth fixing bolts and torque tighten to 45 Nm Hub carrier DE 3 SUSPENSION DISASSEMBLY ASSEMBLY The suspension may be disassembled without the use of any special tools other than a spring compressor if the spring is to be remov
303. ead and valve guides must be at room temperature when fitting guides 4 Locate valve guide in valve guide bore with identification groove s towards valve seat position depth gauge K8 Use depth gauge 18G 1576 4 K16 Use depth gauge 18G 1576 2 5 Position nylon guide 18G 1576 3 in cylinder head press guide into bore using driver 18G 1576 1 until depth gauge contacts top of valve guide bore 6 Check fitted height A of valve guide K8 10 3 mm K16 6 0 mm ENGINE Kaze Valve seat inserts renew CAUTION Triple angle valve seat inserts have been introduced on later K16 engines these inserts are not interchangeable with those fitted to early engines Commencing engine numbers for engines fitted with the new inserts are listed in Information 1 Renew valve seat inserts as necessary CAUTION Do not damage counterbore when removing insert 2 Cool replacement valve seat inserts using liquid nitrogen and press into cylinder head in one continuous operation CAUTION Do not heat cylinder head A 8RM 1102A OVERHAUL 53 ENGINE K8 See illustration 1102A Inlet 29 42 to 29 57 mm B 31 61 to 31 91 mm 35 594 to 35 614 mm D 35 E 35 500 to 35 525 mm F 5 45 to 5 50 mm 5 95 to 6 05 mm H 2 0 mm radius J 0 75 to 1 25 mm K 45 Exhaust A 26 92 to 27 07 mm B 28 73 to 29 03 mm C 33 06 to 33 08 mm D 26 E 33 000 to 33 025 mm F
304. eads of the pipe and sensor before applying Teflon tape to the sensor thread and screwing into the pipe Tighten to 6 Nm Refit the harness plug and top up with coolant For further information on engine management see Section EMN KF 6 RADIATOR FEED amp RETURN PIPES The radiator feed and return pipes are routed through the chassis main side rails feed on the right and return on the left 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 Page 8 CS Lotus Service Notes Section KF Water rail supporting foam blocks Grommet in chassis front closing panel Access into Water pipe chassis rail xe Drain the coolant and remove the front clamshell see sub section BN 4 WARNING The machined edges of the chassis extrusions and the ends of the drive fasteners can present sharp edges and points represent ng a potentially serious hazard It is strongly recom mended that industrial gloves are worn and other suitable precautions taken to provide protec tion from cuts and abrasions Release the hoses from the front and rear end of the water pipe
305. eal 9 Remove 2 thrust washer halves from Number 3 bearing position CAUTION Do not discard thrust washers AN at this stage 10 Remove and discard main bearing shells from cylinder block 82 OVERHAUL Crankshaft inspection 1 Clean joint surfaces on bearing ladder and Cylinder block using suitable solvent DO NOT USE A METAL SCRAPER ON SEALING SURFACES Blow out crankshaft and bearing ladder oilways 2 Measure total thickness of thrust washers removed and compare with new Total thickness of new thrust washer halves 5 22 to 5 30 mm 3 Subtract total thickness of original thrust washers from total thickness of new thrust washers 4 Add figure obtained to crankshaft end float figure obtained 5 If resultant figure will ensure crankshaft end float is within limits specified fit new thrust washers If fitting new thrust washers will not bring end float within limits crankshaft must be replaced Crankshaft end float 0 10 to 0 25 mm Service limit 0 34 mm 6 Record main bearing code letters from bearing ladder Record main bearing code numbers from crankshaft front web First letter and number is Number 1 main bearing CAUTION Crankshafts fitted to later engines have increased main journal diameters Commencing engine numbers for the modified crankshafts are listed in Information The modified crankshafts may be fitted as replacements to engines prior to these engine numbers For inspection pur
306. eaner elements refer above 6 Renew spark plugs 7 Inspect auxiliary drive belt condition 8 Renew cam belt 9 Renew fuel filter 10 Connect Tech 1 2 scanner tool and check for stored codes 11 Inspect A record tailpipe CO Ke par di 4 UA M Bee EROS E i 12 Inspect radiator hoses amp for SECH or leaks Clean radiator finning 13 Check coolant level X X X X 14 coolant 12 months 15 inspect Dang brake Sdt 16 Inspect operation of brake tell tales 17 Inspect brake pad thickness amp disc condition in conditions where brakes are subject to heavy use inspection i be required more frequently 18 Inspect brake hoses pipes amp hydraulic units 19 Check brake fluid level X X X X 20 Renew brake clutch fluid 12 months 21 Check security and condition of front amp rear suspension 22 Inspect dampers for leaks amp performance 23 Inspect front amp rear wheel bearings for play 22 Inspect condition of driveshaft gaiters 23 Inspect steering ball joints A gaiters 25 jInspect free play at steering wheel X X X X X X gt lt gt lt gt lt i service table sn_340R_ 1 emt Continued Page 48 E Lotus Service Notes 340R SERVICE TYPE OPERATION DESCRIPTION Inspect tyre condition amp set pressures Zn 28 Check battery terminals for security amp condition 2
307. ear Ratio Final Drive mph km h 1000 rpm First 2 92 1 5 6 9 0 Second 1 75 1 9 4 15 1 Third 1 31 1 420 1 12 6 20 3 Fourth 1 03 1 16 0 25 7 Fifth 0 85 1 19 4 31 2 Reverse 3 00 1 Page 4 E See Mee CLUTCH Type Friction plate diameter Diaphragm finger clearance Diaphragm finger height new service limit Friction plate thickness new service limit Rivet depth new service limit Friction plate run out new service limit Pressure plate warp service limit BRAKES Type Disc material prior June 98 from June 98 Disc size front amp rear Operation Parking brake STEERING Type Turns lock to lock Gear ratio FUEL S TION 93 116 EC std urban extra urban combined urban extra urban combined 1118 Single dry plate Diaphragm spring cover Hydraulic release 215 mm 1 00 mm 37 5 32 1 mm 42 75 7 4 6 9 5 6 1 00 0 20 0 80 1 00 0 15 Ventilated front amp rear discs Opposed piston alloy front calipers Single piston sliding rear calipers Aluminium metal matrix Cast iron 282 5 mm Tandem master cylinder Cable operation of rear calipers self adjusting for pad wear Rack and pinion 2 4 15 8 1 9 6 1 100 km 29 4 mpg 5 7 1 100 km 49 6 mpg 7 1 1 100 km 39 8 mpg 168 g km 9 9 1 100 km 28 5 mpg 5 9 1 100 km 47 8 mpg 7 3 1 100 km 38
308. earth strap washer Page 20 Lotus Service Notes Section MN The engine management earth cabies are gathered at a insulated binding post at the front of the ECM mounting panel with an earth cable connecting this post to the chassis earth point This arrangement is used to reduce the risk of earth paths being created through the ECM casing 7 WIPER MECHANISM The windscreen wiper mechanism comprises a uni directional motor with an external rotary link a con necting 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 Release the front bonnet latch mechanism from the plinth integral with the motor wheelbox mounting bracket and disconnect the washer tubing 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 3 Remove the wiper arm from the spindle and the spindle rubber surround Spindle rubber surround Wiper motor mounting bracket Bracket fixing bolt
309. ed from the damper unit Removal of the driveshaft from the hub will usually result in separation of the hub bearing two part inner race with likely damage to the integral seal If the hub or hub carrier is being removed for reasons other than for hub bearing replacement the inboard driveshaft should be removed from the transmission and the complete driveshaft assembly retained with the hub carrier and hub With the car on a wheel free lift and with the rear wheels removed 1 If fitted remove the engine bay undertray to provide access to the lower wishbone front pivot 2 Remove the two bolts securing the brake caliper to the mounting plate release the routing clips securing the flexible hose and parking brake cable and support the caliper aside without straining the brake hose Release the single retaining screw and remove the brake disc from the hub 3 Release the bolt securing the outer end of the toe link to the hub carrier noting and retaining the shim washers fitted between the ball pin and conical spacer 4 Remove the two bolts securing the top swivel joint plinth to the hub carrier noting and retaining the camber adjustment shim pack 5 The inboard C V joint is retained in the transmission by a rounded section circlip and may be removed using a special wedge tool T000T1276 or by applying a shock pul to the C V joint body using a slide hammer with a forked end 1998 02 Lotus Service Notes Section DE CAUTION
310. ed loop fuel control system whereby the output signal from oxygen sensor in the exhaust system is monitored by the ECM which constantly adjusts the air fuel ratio to that providing the most efficient conversion of gases by the catalyst A lean air fuel ratio causes a high exhaust oxygen content which reduces the sensor output voltage to the ECM The air fuel ratio is then adjusted to be richer resulting in reduced exhaust oxygen and a higher sensor output voltage In this way the mixture strength constantly sways either side of the ideal setting The sensor is equipped with an integral heating element to ensure that it reaches operating temperature soon after a cold start The heater element supply is controlled by the ECM via a relay in the relay module Using the Lotus Check tool 02 VOLTAGE shows the voltage across the sensor as read by the ECM Once the engine is fully warm and during most idle and driving conditions this voltage will switch rapidly between 0 7 V 1 0 V The FEEDBACK display indicates the current feedback fuelling correction This is shown as a percentage of the mapped open loop value This percentage is continuously updated by the ECM whenever the conditions for closed loop fuelling are present At other times the feedback value will show 10096 indicating that the system is running open loop High values of feedback e g 12096 indicate that feedback is attempting to compensage for fuelling being too lean and low va
311. ee sub section BN 4 and remaining parts 8 WINDSCREEN FRAME The windscreen frame is a single VARI moulding incorporating hollow foam filled sections and includes the fascia top and a forward extending buttress at each side to brace the frame to the front chassis A sepa rately moulded demist duct is bonded to the underside of the fascia top and forms an integral part of the windscreen frame A separate dash baffle is fitted between the underside of the demist duct and the chassis and the aluminium dashboard panel joins the rear edge of the fascia top to the chassis scuttle Fascia top Demist duct Windscreen frame Chassis scuttle Page 12 CS Lotus Service Notes Section 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 requires cutting with reciprocating knife and access to the joints is sometimes ob scured 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 BN 4 and for improved acc
312. ee sub section BN 5 2 Remove exhaust catalytic converter and muffler and if necessary drill out the rivets and remove the exhaust heatshield 3 Disconnect parking brake cables and rear brake hydraulics and remove both rear suspension assem blies complete with driveshafts 4 Release the electrical components mounting plate from the LH longeron 5 Release the engine rear steady arm from the subframe 6 Release the roll over bar stays from the damper top mount tapping block and remove the two bolts each side securing the subframe to the chassis flange Withdraw the subframe and longerons as an assembly together with the floor panel on early cars Note that it is not generally possible to separate a rear longeron from the subframe without damage to one or both components If a longeron is damaged but the subframe is to be re used the longeron must be cut from the subframe 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 and the upper bolts from the front Torque tighten the bolts to 45 Nm If longerons are already fitted to the subframe fit the rear damper mount tapping block to the chassis before fitting the subframe and after bolting up the subframe secure the roll over bar stays using the M10 caphead screw and washer at each side to pass through the longeron and
313. eel 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 BandC C 1998 02 i Straight edge e A FRONT 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 D Dz If the front dimension D is greater than the rear dimension Dz the wheel has TOE IN Ifthe 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 one end and a right hand threaded ball joint at the other 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 60 will increase toe in by just less than 1mm After adjustment tighten the two locknuts to 77 Nm taking care to ensure that the ball joint sockets are aligned at 90 to each other Camber Adjustment Camber is the angle from vertical of the wheel when viewed from the rear and is said to be negative when th
314. eels fitted to engines with plug top coil ignition have reluctor rings with equally spaced teeth If the flywheel is to be replaced it is essential that the replacement is of the correct type 1 Clean flywheel and crankshaft faces Use a clean bolt with two saw cuts along threads and clean adhesive from threaded holes in crankshaft 2 Using assistance fit flywheel to crankshaft fit and tighten new Patchlok bolts to 80 Nm CYLINDER HEAD Cylinder head K8 engines remove CAUTION If crankshaft is to be removed during overhaul it will be necessary to check and record crankshaft end float prior to removing cylinder head 1 Remove and discard camshaft timing CAUTION Do not rotate crankshaft whilst timing belt is removed and cylinder head is fitted pistons will contact the valves 2 Disconnect tensioner spring remove pillar bolt screw tensioner and spring 3 Disconnect ht leads from spark plugs OVER Oe ee ee 12 0552 A 4 Remove 4 screws securing ht lead brackets remove brackets 08 10 12 6 4 ar d iy A Es E ROVERS 9 X9 3 11 9 7 2 12 0549 5 Using sequence shown progressively slacken and remove 12 bolts securing camshaft cover 6 Remove camshaft cover discard gasket Mark distributor flange for refitting reference Remove 2 screws securing distributor Remove distributor discard O ring Remove any debris
315. efit 1 Position a new gasket dry to camshaft cover NOTE Ensure spigots on camshaft cover locate in holes in gasket w Aa Oe 10 777 2 4 6 11 12 0560 Position camshaft cover on cylinder head Fit bolts and tighten progressively in sequence shown to 10 Nm 4 Position timing belt upper rear cover to cylinder head fit screws and tighten to 9 Nm NOTE Longest screw secures cover to x coolant pump 12M 0557A 5 Fit camshaft gear to camshaft hold gear using tool 12 182 and tighten bolt to 8 bolt 35 Nm M10 bolt 65 Nm 6 Align camshaft gear timing mark to cylinder head top face using tool 12 182 7 Fit camshaft timing belt tensioner OVERHAUL 73 ENGINE Camshaft cover and timing gears K16 engines not fitted with plug top coil ignition system refit 1 Clean mating surfaces and inside of camshaft cover If necessary wash oil separator elements in suitable solvent and blow dry 2 Fit new camshaft cover gasket dry to camshaft carrier with either TOP mark towards the inlet manifold or EXHAUST MAN SIDE towards exhaust manifold Camshaft cover with pillar bolts 3 Fit camshaft cover on to camshaft carrier fit 13 bolts at positions 1 and 4 to 15 Fit pillar bolts at positions 2 and 3 Tighten all bolts in sequence shown to 10 Nm Camshaft cover with cast in supports 12M1772 4 Fit camshaft cover on to camshaft carrier
316. elease gasket from sump NOTE Gasket may be re used if in good ra condition Alloy sump 12M1793 14 Progressively slacken then remove 14 bolts securing sump to bearing ladder noting the fitted position of 2 M8 x 60 bolts 15 Using a mallet gently tap sump sideways to release sealant bond remove sump CAUTION Do not lever between sump flange and bearing ladder 16 remove cylinder retainer liner clamps 18G 1736 CAUTION Do not rotate crankshaft until N retainer clamps are refitted GC 12M1396 17 Remove 2 screws suction pipe to oil rail 18 Remove suction pipe 19 Discard O ring 20 Remove 2 nuts securing rail remove 80 OVERHAUL ENGINE Heese 21 NZ 12 1774 Fit cylinder liner retainer clamps 18G 1736 using nylon nuts supplied to retain the clamps Ensure that feet of clamps do not protrude over cylinder bores Tighten bolts sufficiently to retain clamps Big end bearings remove Refit crankshaft timing gear and pulley 2 Fit pulley bolt and washer lightly tighten bolt 3 Ensure that cylinder liner retainer clamps 18G 1736 and nylon nuts are fitted and that feet of clamps do not protrude over cylinder liner bores tne deine ae Lee 8RM 3484B 4 Rotate crankshaft to bring Numbers 2 and 3 pistons to BDC CAUTION Crankshaft will be tight do not rotate crankshaft more than a
317. elt 2 Check correct alignment of timing marks for 90 BTDC 8RM3458A Crankshaft gear dots align with flange on oil pump Camshaft gear mark to right aligns with top 8 Remove crankshaft pulley bolt and washer DEES 9 Remove crankshatt pulley 10 Remove 3 bolts securing timing belt lower cover 11 Remove timing belt lower cover together with seals 12 Remove 3 bolts mounting bracket to engine 13 Remove mounting bracket 12M3756 3 Slacken tensioner backplate screw ensure M124944 tensioner moves fully through its adjustment range and retums under spring tension 4 Push tensioner pulley down to fully OFF 14 Slacken tensioner pulley Allen screw position 15 Slacken tensioner backplate screw 5 Tighten backplate screw to 10 Nm 16 Push tensioner pulley down to fully OFF 6 Using the fingers only fit a new timing belt over position crankshaft timing gear camshaft gear 17 Tighten backplate screw to 10 Nm tensioner pulley and coolant pump drive gear 18 Ease timing belt from gears using the fingers ensure belt is positioned centrally on gears and only pulley and that any slack in the belt is on the 19 Discard timing tensioner pulley side of the belt 7 Clean all traces of Loctite from engine CAUTION Timing belt must always be mounting bracket securing bolts and apply replaced during engine overhaul Do not Loctite 542 to threads of bolts rotate crankshaft with timing belt removed 8 Fit engine mounting b
318. emperature of the catalytic converter rising to a level liable to cause damage to the converter and or engine Stop the vehicle in an area free of combustible materials dry grass leaves etc and allow the converter to cool for several minutes before proceeding with caution The fault should be investigated without delay 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 Maximum safe engine speed is 7 000 rpm at which point the engine management system operates to cut off the fuel supply and safeguard the engine from overspeeding 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 leading to premature wear and possible failure Tachometer Speedometer LCD DISPLAY 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 The top right hand corner of the LCD panel displays the approximate quantity of fuel available in litres The fuel tank capacity is 36 litres and the display reads as follows 0 10 litres Display flashes Refill 11
319. emperature position in conjunction with air conditioning Turning the control progressively clockwise moves the air blend flap to direct an increasing proportion of the airflow through the heater matrix until at the fully clockwise position all airflow is so directed and maximum heat is supplied Air intake via radiator intake duct amp crash structure AE 0 Climate chamber Chassis front wall Heater matrix Fresh flap Blower fan A C evaporator Air blender flap Re circ chassis perforations Screen flap Airflow to footwell Airflow to footwell Footwell flap Demist duct Distribution Screen vent chamber Face level vents one 2000 04 EO Ee Air Distribution Plenum The air distribution plenum is mounted on the top of the chassis sandwiched between the scuttle and the windscreen frame demist duct Air is ducted into the plenum from the blower fan via flexible trunking and flows from the unit into further individual lengths of trunking to the four face level vents each of which is fitted with its own volume and direction controls The plenum contains two vacuum operated flaps to control airflow to the footwell and windscreen vents Footwell Avacuum actuator mounted within the plenum is connected to a flap on the floor of the unit to control airflow to the footwell vents The default position of the flap is to close the footwell vent with vacuum being required to open th
320. engine cooling radiator are also incorporated in this structure The bonded and rivetted alloy chassis structure described above is considered a non serviceable jig built unit to which no structural repairs are approved Superficial cosmetic or non structural localised damage may be 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 and roll over bar together with jig bonded composite rear bulkhead body sills windscreen frame and crash structure and the radiator feed and return pipes heater pipes battery cable and clutch pipe which are all routed within the sill panels 2000 02 ZE Lotus Service Notes Section AF AF 2 CHASSIS STRAIGHTNE HECK 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 taser 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 Position the car on the lift and proceed as follows 1 Identify the tooling holes in the lower surface of each chassis main side
321. ent 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 BETACLEAN 3900 A100B6008V Description Application Degreaser and cleaning agent used for the removal of contamination from the substrate sur face Supplied in 1 litre aluminium container with a BLACK coloured cap Wipe on wipe off type When substrate is very dirty first wipe off the surface with a clean fibre free cloth and dis Dampen 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 Application Cleaning agent which acitvates the old adhesive layer to accept new adhesive Supplied in 250 aluminium containers with a BLUE cap 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 Application Notes Adhesion promotor used to maximise the per
322. er Bolt M6 camshaft carrier Cylinder head bolt Camshaft inlet Camshaft exhaust Drive pin camshaft gear Drive spindle rotor arm Camshaft oil seal Hydraulic tappet ENGINE Collets cap Valve spring cap Valve spring Valve stem oil seal Cylinder head Ring dowel cylinder head to camshaft carrier Cylinder head gasket Valve guide Inlet valve Valve seat insert inlet Exhaust valve Valve seat insert exhaust Blanking plate Screw M6 Gasket coolant outlet elbow Coolant outlet elbow Screw M6 coolant outlet elbow Coolant temperature sensors Sealing washer DESCRIPTION AND OPERATION 7 ON AND OPERATION ENGINE CYLINDER HEAD COMPONENTS K16 NON VVC ENGINES FITTED WITH PLUG TOP COIL IGNITION SYSTEM Spark plug cover Screw spark plug cover htlead and plug tube Oil filler cap Seal filler cap Screws coils to camshaft cover Coil Spark plug Bolt camshaft cover 10 Camshaft sensor 11 O ring 12 Bolt camshaft sensor 13 Camshaft cover 14 Gasket camshaft cover 15 Camshaft carrier 16 Camshatt oil seal 17 Inlet camshaft 18 Exhaust camshaft 19 Bracket multiplug 20 Bolt multiplug bracket 21 Blanking plate 2 off 22 Bolt blanking plate Gasket coolant outlet elbow Coolant outlet elbow Sealing washer Gasket Coolant tem
323. er the standard 3 point inertia reel belts or in conjunction with the roll over bar reinforcement kit the 6 point Competition Harnesses The Kruss Competition Harness uses 70mm wide shoulder straps wrapped around the roli over bar reinforcing frame 70mm lap straps and 50mm crotch straps all of which plug into a single buckle with a bi directional lever release The installation of the harness is illustrated overleaf for both seat types Pay particu lar attention to the threading of the shoulder straps through the adjuster buckle which should be positioned close up against the reinforcing bar Reducer studs are supplied with the harness kit and are to be used for the lap strap anchorages on only the Competition Style seat Recommended seat and seat belt fitment combinations are as follows 1 Competition Driver s Seat A111V6034S 1 off Competition Style Passenger Seat A111V6035S 1 off Roll Over Bar Reinforcement Kit A111A0245 6S 1 off LHD or RHD 6 Point Competition Seat Belt Harness 111003785 2 off 2 Competition Style Seat A111V6035S 2 off Roll Over Bar Reinforcement Kit A111A0245 6S 1 off LHD or RHD 6 Point Competition Seat Belt Harness A111U0378S 2 off 3 Competition Style Seat A111V6035S 2 off using standard 3 point seat belts Note that fitment of the Roll Over Bar Reinforcement Kit precludes the use of the standard 3 point belts and that the Competition Seat Belt Harness is not approved for road us
324. erator Repeat the starting procedure holding the pedal fully down and release immediately the engine starts Idle Speed Engine idle speed is controlled electronically by the engine management computer and is nor mally about 1250 rpm An uprated idle speed is required under certain operating conditions including the engine warm up phase during which time the raised idie helps to speed the time taken for the catalytic con verter to reach operating temperature as well as inhibiting engine stall Idle speed will return to normal automatically when the engine has warmed sufficiently Page 15 N Lotus Service Notes 340R The 340R uses the same close ratio transmission as is fitted to the Elise 111S Compared with the standard transmission the final drive is lowered from 3 94 1 to 4 20 1 in conjunction with raised first and second ratios and a lowered fifth The mph 1000 rpm in fifth drops from 22 9 std to 19 4 close ratio The transmission may be identified by the serial number prifix on the bar coded label fixed to the top of the clutch housing Standard C6BP Close ratio B4BP The only lubricant recommended for the Elise transmission is Texaco MTF 94 available under Lotus part number A111F6017V 3 17 1 i service table sn_tdm_1 tbi Page 16 ONETETUITNMENNNNN 40R G WH amp TY The 340R uses according to market either special Lotus styled 10 spoke magnesium wheels made by Tecnomagnesio or 10 spo
325. erviceable condition If the hydrometer indicates that the battery needs recharging the battery should first be removed 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 Take care when handling the battery to avoid sharp knocks or shocks and keep as upright as possible Beware of the consid erable weight of a battery and take necessary precautions against personal injury Charge the battery follow ing the charger manufacturers instructions while observing these basic rules If the specific gravity is over 1 22 there is no need to charge the battery and charging attempts will only increase the possibility of undesirable overcharge effects Check that the electrolyte level is between the upper and lower markers on the battery case and if necessary add distilled water Depending on state of charge temperature and charger capacity the battery will accept a charging rate of between 3 and 50 amps However at high rates the battery may eject electrolyte through the vents and or become overheated Reduce the charging rate and or stop for a time to allow the battery to cool The recommended bench charge rate is 4 amps When the battery is fully charged s g approx 1 28 allow the battery to stand for an hour before refitting into the battery well and reconnecting the leads see above B
326. ess the two doors Unbolt the topshell mounting bracket at each bottom corner of the windscreen bracket is bolted through the A post panel to a tapping plate bonded to the windscreen frame Remove the windscreen see sub section BN 13 Remove the instrument binnacle and dash panel see sub section BN 12 Release the brake hose pipe connector at the front end of each buttress on the windscreen frame Disconnect the wiper motor harness and windscreen washer tubing Release all relays fuses and har nesses from the buttresses as necessary Use a sealant cutting tool to cut the bond between the buttresses and chassis buttresses and sill panels and between the demist duct and dash baffle Note The joint between the frame and the dash baffle panel is joggled and in order to avoid damage to the baffle the windscreen frame may require cutting to allow sufficient access Fascia top Demist duct Dash baffle Bonded joints C Chassis scuttle 5284 There is short length of vertical joint where the buttress overlaps the sill flange where the sill flange is bonded to the chassis It may be necessary to cut the buttress around this part of the flange in order to remove the frame and then to remove the remaining buttress flange from the sill After releasing the entire bonded joint some manoeuvring of the frame will be needed to withdraw the frame from the baffle panel Release the wiper motor mechanism windscree
327. ess of composite mouldings to be varied in order to pro vide 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 utilises a single moulding for the whole of the nose and front wings and a second one piece moulding for the whole of the rear body aft of the doors These two mouldings 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 The outer surface of a composite panel is sealed by a thin layer of gel coat If the panel is deflected beyond its limits of flexibility the gel coat will be overstressed and cracks will result although the panel will return to its original shape A steel panel similarly treated would become dented or deformed The cracking may be confined to the surface ge coat with no reduction in panel strength but if the damage is more severe the composite structure below the gel coat may be weakened Localised repairs can be made in either case Gel cracks may not appear immediately after overstressing because the effect can be masked by the flexibil ity of t
328. ess oil seal squarely into cylinder block NOTE Do not remove replacer for one minute to allow seal to relax 37 Remove tool 18G 1574 44 45 46 CAUTION Allow sealant to cure for a minimum of 30 minutes before rotating crankshaft Fit flywheel Fit oil pump and front oil seal Fit crankshaft timing gear Fit cylinder head assembly do not fit spark plugs at this stage Fit anew camshaft timing belt Clean joint surfaces Use new gasket dry and fit dipstick tube tighten bolts to 10 Nm NOTE Ensure bolts securing dipstick tube to bearing ladder are flanged head and do not exceed 12 mm in length Support engine and using a socket and suitable torque gauge on crankshaft pulley bolt check that crankshaft can be rotated in a clockwise direction without undue binding rotational torque should not exceed 31 Nm Fit spark plugs and tighten to 25 Nm After installation in vehicle run engine at idle speed for 15 minutes before road testing OVERHAUL 91 ENGINE PISTONS RINGS amp CYLINDER LINERS Pistons and connecting rods remove 92 Suitably identify each piston assembly with its respective cylinder liner Remove big end bearings Using assistance position cylinder block on its side CAUTION Ensure that feet of cylinder liner retainer clamps 18G 1736 do not protrude over cylinder bores Remove ridge of carbon from top of each cylinder liner bore
329. essential that early tappets are not fitted to VVC engines To ensure that correct replacement tappet is fitted measure overall length of tappet j CAUTION Tappets fitted to VVC engines Early tappet Non VVC engines 26 0 mm Later tappet VVC engines 24 5 mm Camshafts and timing gears K8 and all K16 Non VVC engines inspection Camshafts NOTE Carry out camshaft inspection after SCH removal of valves 1 Clean camshaft s camshaft carrier and cylinder head bearing surfaces use Suitable solvent to remove sealant 2 Inspect cams and bearing journals for wear pitting and scoring replace components as necessary 42 OVERHAUL Checking camshaft bearing clearance Non engines K K16 e 12M0563 Position camshaft s in cylinder head and place Plastigage across each journal Fit camshaft carrier and tighten bolts in sequence shown to 10 Nm Do not rotate camshaft s Progressively slacken bolts and then remove camshaft carrier 12M0547 6 Measure widest portion of Ptastigage on each journal Camshaft bearing clearance 0 060 to 0 094 mm Service limit 0 15 mm If clearance is excessive fit new camshaft s and repeat check If clearances are still excessive replace cylinder head and camshaft carrier assembly CAUTION If replacement camshafts are to be fitted ensure they are correct for engine being worked on 7 BAM 3526 Remove drive pin from old
330. essing once the red button Then within 20 seconds press once the blue button This latter action will switch off the microwave sensor with an indication being provided by the alarm tell tale flashing rather than being on steady Note that the sensor will be automatically reinstated next time the alarm is armed Alarm Override Switch A pair of alarm override and immobiliser touch keys are supplied in order to provide for the following situations Vehicle servicing where the battery is to be disconnected Long term parking Loss of both transmitter keys The power sensing circuitry of the alarm will trigger the siren if the power supply is interrupted regardless of the arming status If the main vehicle battery is to be disconnected and triggering of the alarm is to be avoided it is necessary first to turn off the alarm system using the special override key Fit the special key into the switch on the siren housing in the top of the passenger footwell and turn counterclockwise When work on the car has been completed and the battery reconnected ensure that the alarm is activated by turning the override key clockwise Alarm override key operation Page 4 Although the alarm system draws a tiny current if the vehicle is to be parked for an extended period of time over three weeks in summer or two weeks in winter it is recommended to reduce current drain to a minimum by switching off the alarm system with the override k
331. etailed in sub section XA 14 Delete handbrake Remove handbrake lever mounting bracket and cables Remove the lever and spring from each rear brake caliper Alloy fuel tank Remove the steel fuel tank and replace with race alloy tank using original pump and fittings refer to section LH Bend the float arm of the gauge sender to clear the side panel of the new tank Heater duct Remove the heater offtake duct from the radiator the heater trunking and the duct onto the footwell vents Chassis Pack The uprated brake pads racing brake fluid and braided brake hoses are all direct replacements for the stand ard components but note that the rear hoses do not use the clip on the lower wishbone but are tie strapped in two positions to the toe link Road springs the full lightening programme has been carried out the new road springs should be fitted in order to maintain spring compression at full droop Spring rate is the same as standard 340R With the car loaded with driver or 75kg and a half tank of fuel plus all fluids adjust the spring platforms to set the ride height to 100 mm front and 110 mm rear At only this ride height set the suspension geometry to that specified in service notes 340R C and 340R D for either road use or dry track use dependent on customer preference LHD 24 0 hrs RHD inc oil cooler fitment 27 0 hrs Page 39 2000 02 E Lotus Service Notes Section XA 17 340R OIL LER KIT A L
332. etaining bolts or timing belt to rotate crankshaft 5 Fit camshaft gear locking tool 18G 1570 124949 6 Check that timing mark on crankshaft pulley is aligned with mark on timing belt lower cover 2 1861674 124937 7 Fit flywheel locking tool 18G 1674 tighten bolt CAUTION Ensure tooth on tool 18G 1674 engages with teeth on flywheel not the reluctor ring OVERHAUL 11 12 13 14 15 124945 Remove crankshaft pulley bolt and washer Remove crankshaft pulley Remove 3 bolts securing timing belt lower cover Remove timing belt lower cover together with seals 124955 Remove and discard timing belt tensioner bolt Disengage index wire from its fitted position whilst at the same time removing the timing belt tensioner Ease timing belt from gears using the fingers only Discard timing belt CAUTION Timing belt must always be replaced during engine overhaul Do not rotate crankshaft with timing belt removed and cylinder head fitted 12 Camshatt timing belt automatic tensioner refit CAUTION If the sintered gears have been subjected to prolonged oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the belt 1 Clean timing gears coolant pump drive
333. ever 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 Page 21 EG Lotus Service Notes 340R Shift light Seat belts Battery charging Main beam Rear fog Heated windscreen Turn lamps pressure Brakes Battery Charging Tell Tale red 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 Brakes Tell Tale red This tell tale will glow red with the ignition switched on whenever the parking brake is applied or if the level of brake fluid in the master cylinder reservoir has fallen to a dangerously low level Driving the car with the parking 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 If the tell tale should
334. ew M8 x 40 lamp to plate A082W6531F 6 Spring lamp to plate A111B6004F 6 Grommet famp harness 075060432 2 Crash structure Lamp mounting plate gt Coil spring Lamp mounting Harness grommet Plate clamping washer Page 22 Ce Lotus Service Notes Section MN 1 Remove the front clamshell and remove the air intake grille from the crash structure together with two of the Scrivet threaded fixings Transfer these to the top of the clamshell intake aperture pre drilled holes 2 Fitthe M8 Pulserts for the mounting plates into the pre drilled holes in the crash structure and attach the mounting plates 3 Fitthe driving lamps to the mounting plates using the M8 x 40 plastic screws and compression springs Release the tied back harness and route through the crash structure using new grommets and connect to the lamps protecting the connector plugs with silicone grease or petroleum jelly 4 Fitthe new grille to the clamshell and refit the clamshell MN 9 HARNESS ROUTING The main harness runs from the main fusebox relay station at the passenger side of the front services compartment forwards across the front of the chassis well to feed the heater motor horn and driving lamps and rearwards through the scuttle where it divides into branches running a through the scuttle beam and across the dash top for the instrument pack and switchgear and b along the cockpit centre tunnel to the rear of the
335. ey and utilising other security measures includ ing the automatic immobilisation feature as may be deemed appropriate The override facility may also be used in order to allow recovery of the vehicle in extreme condi tions for example if both transmitter key batteries have been allowed to run down or are lost or faulty The immobilisation feature will remain operative and must be overridden by switching on the ignition and inserting the immobiliser touch key into its socket on the side of the column shroud for about a second until the adjacent LED is extinguished In order to protect against the loss of all keys it is essential that the alarm override keys and immobiliser touch keys are kept separate from the transmitter keys but the owner should be reminded that if the car is to be left for servicing or repairs the override key must be available to the technician Immobiliser touch key Dynamic Transmitter Coding Each time a transmitter key is used the coding in both transmitters and the control unit is changed for optimum code copying protection When using a transmitter which was not last used to operate the system it will be necessary on the initial command to press the red button twice in order to synchronise the codes in the three elements Be sure to press the button for a whole second to allow the complete code to be transmitted Functional Test To test that the alarm system is operating correctly carry out the followi
336. f reverse gear A DN Kee d Va Hours NS I ee 37M1277 REVISED 12 97 MANUAL GEARBOX To prevent any further movement of the 3rd 4th synchro sleeve 5 and engagement of 4th gear the spring on the lock plate 3 moves the lock plate into the machined groove 7 above the abutment 4 5 CERE A eR e M 37M1278 DESCRIPTION AND OPERATION 9 MANUAL GEARBOX 0 0 Selector shafts 37M1147 Selector Shaft Components 4 Slide 5th reverse gear selector off Sth reverse selector shaft Roll pin 5 Slide 3rd 4th and 5th selector forks off 5th reverse gear selector 5th reverse selector shaft 3rd 4th gear selector fork 5th gear selector fork 5th reverse selector shaft 1st 2nd gear selector fork tst 2nd selector shaft CAUTION Two types of selector shaft assemblies have been fitted Type A selectors are manufactured from cast steel whilst type are manufactured from aluminium bronze and are gold in colour Do not interchange selector forks or shafts between type A and B assemblies 1 Identify each selector fork and its fitted position to the relevant selector shaft Slide 1st 2nd gear selector fork off 1st 2nd selector shaft 2 Slide 1st 2nd selector shaft out of 5th gear selector fork and 5th reverse gear selector 3 Using a suitable punch remove roll pin securing 5th reverse gear selector discard roll pin
337. features a throttle body housing a single throttle butterfly valve with position sensor feeding into an intake plenum chamber with four individual intake tracts each of which is fitted with a fuel injector positioned to spray fuel onto the back of the intake valves Standard engines use a lightweight moulded plastic plenum manifold whereas on VVC engines the manifold is alloy Fuel delivery quantity is controlled by the length of time pulse width for which the solenoid operated injectors are energised with the injectors of standard engines grouped in pairs 1 with 4 and 2 with 3 whereas the VVC engine uses a fully sequential strategy with individual control of each injector The air fuel ratio is calculated by the ECM using a three dimensional map to provide a basic fuelling specification under various operating conditions In order to refine the fuel delivery and cater for special conditions various types of compensation are provided Cranking enrichment During cranking when engine speed is below about 400 rpm the injection pulse width is increased dependent on coolant temperature to aid starting After start enrichment Immediately after starting the pulse width is increased but decays at a rate dependent on coolant temperature Acceleration enrichment Signals received from the throttle position and MAP sensors which indicate acceleration is demanded will prompt additional fuel for smooth and ready response Overrun fuel cut off
338. firmly inflated i 1899 03 Lotus Service Notes Section GF 4 Immediately drive for 6 12 miles 10 20 km or to the tyre depot if nearer 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 the 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 addi tional charge for cleaning the sealant off the tyre before repair and that any subsequent repairs may not be guaranteed 6 Replace the inflator canister 4 SECURITY WHEELNUTS On cars so equipped each of the four road wheels is fitted with one security keyed wheel nut in order to deter theft and vandalism The special splined security nut requires a matching key coded socket before it may be removed using a standard 19mm wheelbrace For aesthetic purposes the coded nut is capped by a metal cover which may be removed using an extractor tool stowed together with the key coded socket in a grommet in the windscreen buttress at the right hand rear corner of the front services compartment Push the extractor over the cover until it clips onto the rim and withdraw the cover Mate the key coded socket with the nut and undo using a standard 19mm wheelbrace Extractor tool Nut cover Security nut Coded socket 1999 03 SC
339. fit 1 Ensure 2 locating dowels are fitted in camshaft carrier 2 Fit new VVC housing gaskets 12M3500 3 Lubricate exhaust camshaft cams and joumals with engine oil position camshaft in cylinder head 4 Lubricate cams and joumal of front and rear inlet camshafts with engine oil 5 Lubricate control shaft with engine oil me OVERHAUL 63 ENGINE 12 3501 1801770 6 Position control shaft in camshaft carrier ensuring that shaft is fully seated joumals and centre of slot in shaft is aligned with cylinder head mating surface of carrier 7 Position front and rear inlet camshafts and VVC assemblies in camshaft carrier at the same time engaging teeth of control shaft in VVC assemblies 8 Check that bolt holes in VVC housings are aligned with bolt holes in camshaft carrier that centre of slot in control shaft is still aligned with cylinder head mating surface of carrier and timing plates 18G 1770 1 front and 18G 1770 2 rear are correctly located in the control sleeves and control shaft is still seated in journals CAUTION If bolt holes are not correctly AN aligned or slot in control shaft has moved re position VVC assemblies and shaft as necessary until alignment is correct 9 Fit and tinger tighten slave bolts front and rear VVC assemblies to camshaft carrier NOTE Slave bolts must be replaced with new Patchlok bolts when camshaft
340. fitted with a sleeve A Slacken tensioner backplate screw ensure 10 11 12 M124926 NOTE Non VVC camshaft timing gears and tensioner spring illustrated tensioner moves fully through its adjustment range and retums under spring tension Push tensioner down to fully OFF position tighten tensioner backplate screw to 10 Nm Using the fingers only fit a new timing belt over crankshaft timing gear and then over camshaft gears keeping belt taut between crankshaft timing gear and exhaust camshaft gear Ease timing belt over tensioner pulley and coolant pump drive gear ensuring belt is positioned centrally on gears and pulley Ensure inserts are fitted in timing belt lower cover Fit timing belt lower cover ensuring correct position of seals tighten screws to 9 Nm 8 OVERHAUL ENGINE 99291 A 6171920 V M124927 13 Fit crankshaft pulley to crankshaft timing gear ensuring that indent on pulley locates over lug on gear 14 Secure with crankshaft pulley bolt and washer tighten to 205 Nm 15 Remove camshaft and flywheel locking tools I3 M124928 Er NOTE Non VVC camshaft timing gears EN and tensioner spring illustrated 16 Slacken tensioner backplate screw and tension timing belt by applying finger pressure to tensioner backplate 17 With tensioner pulley against timing belt and backplate held in position tighten backplate screw to 10 Nm 18 Rotat
341. foam sleeving to supress rattles In July 98 the pipe specification was upgraded and added a metal braiding in order better to resist pipe expansion and loss of clutch release travel in conditions of extreme heat Service replacement pipes are of only the later type with the RHD variant supplied with a separate front end U bend to aid assembly The pipe should not be withdrawn from the car without attaching a guide wire with which to aid routing of the new pipe 1998 1 Lotus Service Notes Section Replacing Hydraulic Pipe During this operation take all appropriate precautions to protect against damage caused by contamination of painted surfaces with brake fluid 1 For optimum access remove the left hand side dash panels see Service Notes sub section BN 12 and the LH sill coin tray Remove the engine bay undertray diffuser panel and the shear panel beneath the fuel tank 2 Release the clutch pipe from the master cylinder and slave cylinder and immediately cap the cylinder ports to minimise fluid loss and prevent dirt ingress Drain the pipe of fluid and cap both ends to prevent drips and fluid contamination of painted surfaces 3 ease withdrawal of the pipe straighten out the right angled connector at the rear end of the pipe and reaching into the rear end of the sill remove as much of the foam sleeving from the pipe as can be accessed Remove the grommet from the scuttle baffle panel 4 OnLHO cars
342. fore pressing the retaining barb and unplugging the harness connector s On standard cars the MAP sensor is contained within the ECM body with the sensor hose connecting to a spigot on the underside of the unit On pre boot box cars release the three screws securing the ECM to the side panel and withdraw the unit On post Sept 98 bootbox cars the ECM is mounted at the rear of the engine bay standard modules fixed to the bootbox front wall and VVC module using a steel mounting bracket To release the VVC module undo the clamp top bolt the second ECM top fixing and lift out the ECM em197 MAP sensor hose EMN 5 RELAY MODULE type ECM top fixing Clamp top fixing SS A NUR We Ke y 2 eS IN un li lt ANA WE 657725 t The MEMS relay module is single unit serviced only as one component The unit incorportates the following relays Main Relay Supplies current to the ECM when the ignition is switched on When the ignition is switched off the ECM will keep the main relay energised for a short period whilst the IAC valve is driven to its power down position ready for the next engine start Fuel Pump Relay Energised by the ECM for a 3 second period each time the ignition is switched on Continuously fed during engine cranking and while the engine is running Starter Relay Energised by the cranking output from the ignition switch Supplies current
343. formance of the bonding TER the cleaned and or activated surface and the adhesive compound Supplied in 250 ml aluminium con tainer with GREEN coloured cap 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 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 5404 A082B6337V Description Application Adhesion promotor used to maximise the performance of the bonding between the cleaned and or a
344. from spark plug recesses remove and discard 4 spark plugs OVERHAUL 23 ENGINE 12M 0548A 11 Use tool 12 182 to hotd camshaft gear against rotation 12 Remove bolt and plain washer securing camshaft gear 13 Remove camshaft gear 14 Remove screws securing upper part of timing belt rear cover to cylinder head and screw securing rear of cover to coolant pump remove cover NOTE This is the longest of the rear cover AN securing screws 15 Check and record crankshaft end float 16 Using sequence shown progressively slacken 10 cylinder head to oil rail bolts Remove bolts and store in fitted order CAUTION Removal of cylinder head bolts will result in a tightening up of the crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G 1736 are fitted 17 Using assistance remove cylinder head assembly CAUTION Cylinder head is dowel located do not tap it sideways to free it from cylinder block Place cylinder head on wooden blocks to prevent damaging valves 18 Remove and discard cylinder head gasket 24 OVERHAUL ENGINE esee Cylinder head K16 Non VVC engines fitted with distributor remove CAUTION If crankshaft is to be removed during overhaul it will be necessary to check and record crankshaft end float prior to removing cylinder head 186 1570 12 1770 19 Asse
345. g iii Ensure that all electrical loads e g lights are switched off iv If the vehicle is fitted with CATS coded audio equipment check that the security code is available for entering on reconnection v 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 con nected the resultant short circuit with heavy sparking and current flow could cause serious burns Battery Reconnection i Check again that all electrical loads are switched off i Connect the positive battery cable first followed by the negative earth cable iil 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 If applicable turn the alarm system back on at the siren housing 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 Where applicable enter the CATS code into the audio equipment Battery Chargin If the state of charge of the battery is in doubt the specific gravity s g of the electrolyte should be checked using a hydrometer An s g of 1 22 is typical of a 6596 state of charge considered to be the minimum s
346. g circuit may be faulty Turn Tell Tal 956 ee urn Tell Tale dl When the left hand or right hand turn indica E daten ED van 274 tors are operating this green tell tale flashes uni son The flasher relay may also be heard to operate If the tell tale fails to light or flashes at an unusual or irregular rate the operation of the turn indicator Se lamps should be checked immediately Parking Brake Teil Tale 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 goes out Brakes Tell Tale If the red brakes tell tale should light any time after the check period stop the car immediately as the level of brake fluid in the master cylinder reservoir has fallen to a dangerously low level 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 spongey operation and extended pedal travel The split brake circuit should ensure that emergency braking will remain but the car should not be driven until the fault has been rectified Cil Pressure Tell Tale 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 s
347. g each over centre latch and lifting off the fairing Lift out the rear window from its channel and store carefully Soft Top Roof Erection To erect the soft top roof first fit the rear window and roll bar fairing see above Retrieve the folded roof assembly from the luggage compartment or from behind the seats unpack from its stowage bag if applicable and open both doors Then 1 Unroll the roof and identify the two side rails Plug the spigot on the front end of the right hand rail into the socket at the top of the windscreen pillar Clip the rear end of the rail into its retainer on the roll bar by pushing the rail forwards at the same time as pressing inwards on the rear end Fit the left hand rail in a similar manner Fold roof bow forwards Windscreen Clipping rear end of cant Cant rail spigot 2 Unclip the two roof bows from their stowage site behind the seats and fit into their locating holes in the roof side rails Note that both bows are identical Fold both bows forwards Page 2 Lotus Service Notes Section 3 Laythe soft top in position and hook the whole length of the lip on the front edge of the roof beneath the retaining strip on the windscreen header rail Centralise the roof by wrapping the sides of the soft top around the side rails and clipping the three press stud fasteners on the inside face of the rails Locating roof front lip Clipping roof to side rails Ensure that
348. g force applied to the inner bearing races Updating to the later specification is also recommended if the front hubs are to be removed for any reason Description Part no Qty Front Hub Clamp Bolt Set 111 01375 1 comprising Bolt M16 x 100 bearing clamp A111W2185F 2 Nut M16 Nyloc bearing clamp bolt A111W3159F 2 Thrust Washer outer 111 0117 2 e Lotus Service Notes Section CG Thrust Washer inner 111 0118 2 Dust Shield front wheel bearing B111C0076F 2 Washer M16x30x2 A111W4171F 2 The M16 clamp bolt set is a direct replacement for the M12 set and it is recommended that at the time of fitting the hub is removed from the bearing and the condition of the hub spigot carefully examined If any signs of bearing inner race movement on the hub are evident the hub and bearing should be renewed and assem bled with the new bolt set To Replace Wheel Bearing 1 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 Withdraw the brake disc from the hub 2 Release the four fixing screws and remove the lower swivel joint from the hub carrier 3 Release the two bolts and taking care to retain the camber adjustment shim plates separate the steering arm from the hub carrier Remove the hub carrier to a bench Inner thrust washer Outer thrust washer M16 bolt M16 Nyloc nut Flat washer Dust shield 1 Zags NSSNNNN
349. g models MGF Rover 114 and 214 414 New Rover 214 216 218 and BRM New Rover 414 and 416 Coupe Cabriolet Tourer and Sports Models Rover 25 Rover 45 and Rover 75 Publication Part No RCL 0057ENG 5th Edition Published by Rover Technical Communication 2000 Rover Group Limited INTRODUCTION CONTENTS Page INTRODUCTION INTTRODUGTION ahaa tee etit 1 REPAIRS REPLACEMENTS 22 22 2 22 222 2225 1 SPEGIFIGATION seed et d EES des ne d Pot ho 2 ENGINE NUMBER LOCATION 2 ENGINE SERIAL NUMBER PREFIXES 2222 2 2 9 2 COMMENCING ENGINE NUMBERS 2 2 2 5 9 22 K16 Non VVC engines fitted with automatic timing belt tensioner 2 K16 Non VVC engines fitted with modified camshafts and cylinder heads 3 Cylinder heads fitted with triple angle valve seats 3 Modified crankshafts eem 3 INTRODUCTION INTRODUCTION How to use this manual To assist in the use of this manual the section title is given at the top and the relevant sub section is given at the bottom each page To help readers find the information they need the first page of each section is marked with a black tab In addition the symbol at the top of each RH page identifies each section or group of sections
350. g the optimum upward gearchange point for the exploita tion of maximum vehicle performance The red RPM tell tale will light at engine speeds above 7 600 rpm Page 22 EG Lotus Service Notes 340R Speedometer This instrument displays in analogue form vehicle road speed in either MPH with a secondary scale in km h or km h according to territory Recalibration of the needle position will occur during a three second period following ignition switch on The instrument face is illuminated when the marker lamps are switched on Tachometer The tachometer indicates engine speed in revolutions per minute A safeguard in the engine manage ment system limits engine speed to 8 000 rpm 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 leading to premature wear and possible failure Recalibration of the needle position will occur during a three second period following ignition switch on The instrument face is illuminated when the marker lamps are switched on The lenses of both speedo and tacho are treated with an anti refletcive coating LCD DISPLAY PANEL A liquid crystal display LCD panel is in corporated into the speedometer in order to Distance recorder Trip display display fuel level coolant temperature total distance and trip distance The panel is blank until the ignition is switc
351. gear and tensioner pulley 18G 1570 M124961 2 Check correct alignment of camshaft gear timing marks fit camshaft gear locking tool 18G 1570 D NM M124962 3 Check that crankshaft gear timing marks are aligned with flange on oil pump 90 BTDC OVERHAUL 1861674 M124937 Fit flywheel locking tool 18G 1674 M124956 Fit timing belt tensioner ensuring that index wire 15 positioned over pillar bolt and that tensioner lever is at 9 o clock position Fita new tensioner securing bolt and tighten bolt until it is just possible to move tensioner lever Using the fingers only fit a new timing belt over crankshaft gear then camshaft gears tensioner pulley and coolant pump drive gear ensuring that the belt run between the crankshaft gear and the exhaust camshaft gear is kept taut Check that timing belt is positioned centrally around gears and tensioner pulley Ensure inserts are fitted in timing belt lower cover 10 11 12 13 ENGINE Fosse 124953 Fit timing belt lower cover ensunng correct position of seals fit screws and tighten to 9 Nm Fit crankshaft pulley to crankshaft gear ensuring that indent on pulley locates over lug on gear Fit crankshaft pulley bolt and washer tighten to 205 Nm Remove camshaft gear and flywheel locking tools 18G 1570 and 18G 1674 OVERHAUL 13 ENGINE M124957 14 Using 6 mm Allen key rotate
352. ght and efficiency but is taken to a further extreme to focus on driving pleasure and is aimed at the enthusiast driver and for occasional circuit use Features include a non structural minimalist body without doors or roof structure combined with separate close fitting carbon fibre mudguards translucent body side panels a carbon fibre rear aerofoil mounted on alloy side plates and a special oval section steel roll over bar Sport suspension is fitted complete with the uprated and adjustable front anti roll bar The vehicle has proven to be an extremely rare phenomenon within the motor industry as it is virtually unknown for a concept vehicle to be productionised without drastic modification The styling concepts first shown at the 1998 International Motor Show at the Birmingham N E C have remained true to their ideals in production form In fact its uniqueness continues through to the rigouress acceptance criteria of the European Whole Vehicle type approval authorities no mean feat for a vehicle with these features 340R TD TECHNICAL DATA Dimensions Overall length 3620 mm Overall width 1702 mm Overall height at kerb weight 1080 mm Wheelbase 2300 mm Track front 1432 mm rear 1459 mm Ground clearance at kerb weight 110 mm Approach angle 12 4 Departure angle 28 Unladen weight total 701 kg gt inc full front 278 kg gt fuel tank rear 423 kg gt Maximum weight total 928 kg incl front 387 kg occupants
353. gine will continue to run in sequential fuelling mode until ignition switch off If the ECM detects any faults with cam period measurement during start up and initial running the ECM will try and drive dependent on the cause of the fault the mechanism to minimum cam period Engine speed will be limited to approx 5 600 rpm and the idle speed will be raised If the ECM loses the cam priod signal during running the cam period will remain frozen at the last valid period Engine speed may be limited as low as 5500 rpm depending on cam period when the fault occured The idle speed will be raised for the rest of the journey Note that a cam period measurement fault will only be recorded by the ECM if the fault is detected at start up or during initial running When refitting or replacing a cam angle sensor use a new ring and tighten the fixing screw to 6 Nm Camshaft position sensor 6112011 16 0 1 E Lotus Service Notes Section EMN The inlet cam period is determined by a hydraulic control unit HCU mounted on the right hand front of the cylinder head The HCU uses two solenoids to operate a spool valve and control a piston and rack mechanism which outputs from the HCU via a control shaft to the two VVC mechanisms The ECM energises one solenoid valve at a time to drive the VVC mechanism either towards maximum or towards minimum inlet cam period The desired period is calculated by the ECM primarily using engine s
354. glass cleaners may be used if required but liquid or paste type abrasive polishes should NOT be used Stone Chip Protection Astone chip protective film set tailored specifically for the Exige is available under part number A111V0627S Seats amp Seat Belts Standard equipment consists of 111S cloth leather option trimmed seats and inertia reel seat belts Cars may be specified with a factory fit option of sports style seats trimmed in Alcantara suede using 340R seat runner sliders on the driver s side and the 340R fixed seat frame for the passenger Packaged with this seat option are 340R 4 point harnesses using a shoulder harness anchorage bar bolted across the roll over hoop For competition use the roll over bar reinforcement kit with removeable forward strut may be dealer fitted Interior A trim pack option comprises Alcantara suede in either blue red silver or black applied to the door inserts sill trims steering wheel centre pad and dash inserts 2000 03 Lotus Service Notes Exige XIGE C FRONT SUSPENSIO The Exige is fitted with the Elise Sport suspension package which includes adjustable spring platform Koni dampers with Exige specific springs and the uprated front anti roll bar in Nylon chassis mounting blocks The standard setting for the front anti roll bar is the central of 5 available holes Steering rack positioning plates from the Sport kit are used to suit the specified mid laden ride height of 112 122
355. gt 20 G i2V SIDEL AMPS SEE SHEET 9 CIGAR LIGHTER 2V 10 BS Bw BS Bw zx LH REAR RH REAR m SPEAKER SPEAKER E SHEET 13 L o E Lotus Service Notes Section POWER 4 GROUND STRUCTURE FRONT HARNESS CONNECTOR E MAXIFUSES D IGNITION SWITCH gt J HEADLAMP CIRCUIT Co lt EN lt ENGINE H FUEL PUNP REAR HARNESS CONNECTOR ENGINE MANAGEMENT RHC SHEET 14 EG Lotus Service Notes Section MN INTER HARNESS CONNECTORS CONNECTOR ON CONNECTOR ON FRONT amp REAR HARNESS CONNECTORS FHC A RHC ENGINE HARNESS CONNECTOR EHC 1 ENGINE HARNESS CONNECTOR 2 EHC 2 ENGINE HARNESS CONNECTOR 3 EHC 3 ar ALARM HARNESS amp sm DEI HARD MAIN HARNESS MATING HARNESS SHEET 19 s Service Notes Section MN FUSES E FUSEBOX A NO RATING APPLICATION REAR FOG LAMP 02 2 ALARM 03 15 INTERIOR WIPER NOTOR 3A REVERSE LAMP 06 7 54 DIRECTION INDICATORS 07 SA IGNITION SERVICES 08 7 STOP LAMPS amp BATTERY SERV
356. gue to help stabilise the soft top and to cover the tongue fixings and a small D section seal is glued to the header rail ahead of the tongue carrier The following procedure describes the fitting of new tongues and carriers to a new windscreen frame to which the door weatherstrip has already been fitted A similar procedure will also apply to the refitting of dismantled components Tongue strip D section seal Tongue strip Moulded Hollow foam plastic filled windscreen Carrier header rail Moulded Gripper strip 5270 D section seal Windscreen header rail Windscreen Spigot hole for roof cant rail 0269 28 i Lotus Service Notes Section BN 1 Dry fit the RH moulded carrier and alloy tongue strip using a 12 mm diameter dowel the cant rail spigot hole and aligning the rear edge of the carrier with the header rail edge Drill a 2 4 mm diameter pilot hole at the fixing point by the cant rail location and at four of the header rail fixing points drilling through the carrier and into the header rail Retain by temporarily fitting the screws at these points 2 Dry fit the LH carrier and tongue strip and cut the two parts to abut neatly with the RH halves Drill pilot holes for the LH parts and retain with four screws as for the RH side 3 Remove the carrier and tongue strip fixings and trim the top of each door weatherstrip to fit in the recess in the tongue carrier Bond the weather
357. h a weight saving of over 4 kg the Titanium muffler A340M6011S may be fitted with the catalytic converter and will meet road noise regulations as well as RAC MSA Section A noise regulations On track based cars for further performance enhancement between 5 000 and 6 500rpm and with a weight saving of over 4 kg the Track exhaust muffler A340S6008S may be fitted which incorporates a cat replacement pipe This part complies with RAC MSA Section A noise regulations MOT Regulations U K If the car is required to meet the U K MOT regulations the standard engine breather system must be retained together with the charcoal canister and the Motorsport catalytic converter A340S6010S Deletion of the standard breather system for track use allows increased mid range spark advance to be applied If the standard breather system is retained for road use it is recommended to use 97 RON Super Unleaded fuel in order to provide a higher resistance to detonation when using the track specification spark advance curve If the idle air control valve has been removed check that the idle speed is within tolerance as a low idle speed may cause excessive HC emissions 2000 02 SSES Eo Lotus Service Notes Section XA 3 340R LACH TIMER LEVEL 1 A340NO LSL392 The Tach Timer is produced by Stack specifically for the 340R and consists of a replacement tachometer with an LCD panel to display the available features which include Multi level
358. h the associated spacers and shim washers see below TS 1999 01 Lotus Service Notes Section DE Lotus Service Notes Section DE Assembly procedure toe link outboard fixing earl joint 1 Use proprietary degreaser e g Silkolene Contact Cleaner to degrease the female thread the ball joint checking that the bottom of the hole is not restricted by compacted old adhesive limiting the penetration of the fixing bolt If necessary use a small screwdriver or similar to ensure all adhesive is removed and dry the thread with a paper towel and airline When fully clean measure the depth of the threaded hole using a depth gauge or narrow steel rule Minimum depth 26 mm f the dimension is less than this figure replace the ball joint 2 Establish the correct bolt and washer configuration for the number of bump steer shim washers noted on disassembly refit the original shim washer stack 1 2 or 3 shim washers 10 60 bolt A111D0054F 1 8mm flat washer beneath bolt head A111W4163F 4 shim washers M10x65 bolt A111D0065F 3 0mm flat washer beneath bolthead A111W4180F 5 shim washers M10x65 bolt A111D0065F 1 8mm flat washer beneath bolt head A111W4163F Note that the great majority of cars are built with 4 shim washers 3 Assemble the bolt with washers and spacer into the hub carrier and check the following two dimensions i The exposed shank length Specification 1 0 to 9 0 mm ii exp
359. haft is clamped into the pedal box and serves ail three pedals which are themselves common extru sions with the throttle pedal being a narrower section than that used for the brake and clutch The brake and clutch pedals use cylindrical coated alloy trunnions to actuate their master cylinder pushrods with the bore for the brake pedal trunnion being machined nearer to the pedal pivot than in that for the clutch pedal The top end of each pedal uses maintenance free self lubricating plastic pivot bushes and an extruded footpad is bolted or rivetted to the bottom end of the pedal The throttle pedal uses a ball jointed rod and multiplier lever to operate a throttle control cable which is routed along the cockpit centre beneath the gear lever and parking brake lever trim panels Throttle Throttle cable linkage multiplier lever Stoplamp Throttle switch pedal upstop Scuttle bracket Throttle rod Throttle downstop Footpad pivot pivot trunnion shaft bush 755 13 48 Lotus Service Notes Section JH The pedal box may be removed from the car complete with pedals but to avoid hydraulic fluid loss and the necessity for subsequent bleeding the brake and clutch master cylinders should be released from the pedal box before removal 1 Release brake master cylinder from the pedal box see sub section JH 7 and ease the cylinder clear of the pedal box to disengage the pushrod without straining the hydraulic pipes
360. hanged during 1997 Early type with tapped holes in the hub carrier Apply Permabond A025 high temperature threadlocking compound orange A912E6800V to the threads of both shallow caphead M10 setscrews and torque tighten to 44 Nm Later type with through bolts and nuts Torque tighten the bolts and self locking nuts to 62 Nm Note that if an early car is updated with the later type hub carrier the top ball joint carrier may have to be relieved to provide clearance for the caliper mounting plate top fixing nut Supporting the inner race of the hub bearing press the hub fully into the bearing from the outside Re assemble the suspension in reverse order to dis assembly referring also to sub section DE 3 After torque tightening the rear hub nut to 220 Nm lock the nut to the driveshaft by peening the nut flange into the driveshaft slot Pump the brake pedal to reposition the pads before driving the car SH 1999 01 CEN Lotus Service Notes Section DE 6 WHEEL SPEED SENSOR The wheel speed sensor is used to provide a road speed signal to the speedometer and is mounted on a bracket fixed to the left hand rear hub carrier The sensor is easily damaged and if a driveshaft is to be removed the sensor should first be withdrawn from its mounting bracket The gap between the sensor tip and the pole wheel toothed ring pressed onto the driveshaft is critical and should be checked whenever a driveshaft is re assembled into a hub carrie
361. he Repair Manual for the model concerned This manual is divided into 3 sections Description and Operation Overhaul and Data Torque amp Tools To assist filing of revised information each sub section is numbered from page 1 The individual overhaul items are to be followed in the sequence in which they appear Items numbered in the illustrations are referred to in the text Overhaul operations include reference to Service Tool numbers and the associated illustration depicts the tool Where usage is not obvious the tool is shown in use Operations also include reference to wear limits relevant data torque figures and specialist information and useful assembly details WARNINGS CAUTIONS and Notes have the following meanings WARNING Procedures which must be followed precisely to avoid the possibility of injury CAUTION Calls attention to procedures which must be followed to avoid damage to components NOTE Gives heiptul information References With the engine and gearbox assembly removed the crankshaft pulley end of the engine is referred to as the front Operations covered in this manual do not include reference to testing the vehicle after repair It is essential that work is inspected and tested after completion and if necessary a road test of the vehicle is carried out particularly where safety related items are concerned INTRODUCTION Dimensions The dimensions quoted are to design engineering
362. he Vehicle Battery Before disconnecting the battery ensure that the alarm system is disarmed On reconnection of the battery the alarm will automatically be set Have the transmitter ready to disarm Component Location The alarm system components are located as follows Electronic Controller Mounted in the front services compartment chassis well outboard of the battery Siren Unit Mounted on the passenger side of the scuttle beam Immobiliser Module Mounted in the electronics box on the cabin rear bulkhead Intrusion Sensor Stuck to engine ECM in bulkhead electronics box The engine lid sensor switch is mounted at the rear of the lid aperture The front access lid sensors are mounted at the front of the apertures Intrusion microwave sensor Engine lid sensor Tell tale Front lid sensor Electronic controller Immobiliser module Tell Tale Lamps Bulb Check In order to check that the warning systems are operative all the tell tale lamps should light for two seconds following ignition switch on If any lamp should fail to light there is likely to be a fault on that warning circuit Seat Belt Tell Tale red As a reminder to fasten the seat belts the seat belt icon the tachometer will flash red for about eight seconds following ignition switch on and will then be extinguished Oil Pressure Tell Tale red This red tell tale warns of low engine oil pressure The lamp will be lit when
363. he air cleaner bracket at the left hand side of the engine bay At intervals specified in the maintenance schedule the filter unit should be renewed 1 WARNING The fuel in the filter and connecting pipework remains pressurised after switching off the ignition Before disconnecting the fuel line carry out the fuel pressure relief procedure detailed in sub section LH 3 2 Remove the air cleaner cover for access and use two spanners to release the inlet connection from the front end of the filter Use an absorbent cloth to collect any draining fuel Release the push fit connector Page 4 Lotus Service Notes Section LH Filter outlet pipe Push connector CF Fuel rail feed hose SS Fuel filter Filter holder Filter inlet connection Push connector detail between the filter outlet pipe and the engine feed hose by pressing the release collar towards the connec tor and sliding off the pipe end Press back the retaining clip and withdraw the filter from its carrier necessary remove the outlet pipe from the filter Fit the new filter into the carrier ensuring that the retaining clip is properly engaged and connect the two fuel hoses Note the direction of flow arrow on the filter body which must point towards the engine Start the engine and check for fuel leaks LH 5 FUEL TANK The fabricated steel fuel tank is mounted within the chassis crossmember between the engine bay and passenger compar
364. he alarm may be armed with out the intrusion sensor or battery interruption ciruits being active by with the alarm disarmed hold the trans mitter button pressed for a 4 second period This will be acknowledged by 3 flashes of the hazard lamps and blinking of the alarm tell tale Note Intrusion sensing will automatically be reinstated the next time the alarm is armed not inhibit operation of the radar detector by placing bags or large objects against the cabin rear bulkhead 2000 03 E Lotus Service Notes Transmitter Key Battery Replacement The batteries for the key head transmitters should be renewed at six monthly intervals to Retaining ensure continuity of operation replace transmitter battery a Use a thin blade to prise apart the two halves of the transmitter key head and with draw the battery b The transmitters are powered by a 3v long life lithium battery type CR2032 With normal use this should last between 3 and 5 years After opening the new battery packag ing touch only the sides of the battery and fit the battery into the key case with the positive side upwards as shown c Press the battery case together Batteries Disconnecting the Vehicle Battery Before disconnecting the battery ensure that the alarm system is disarmed On reconnection of the battery the alarm will automatically be set Have the transmitter ready to disarm Component L
365. he cam belt 4 Use special too TO00T 1280 to hold the inlet camshaft pulley and release the retaining bolt Withdraw the pulley from the camshaft and timing belt 5 Fit the new pulley to the camshaft with the T mark just above the timing mark on the exhaust camshaft pulley and the dowel engaged in the pulley slot Use special tool T000T 1280 to hold the inlet camshaft pulley and tighten the M10 retaining bolt to 65 Nm 6 the inlet camshaft to align the inlet pulley T mark with the exhaust pulley EXHAUST mark and slip the belt onto the pulleys ensuring that the drive side of the belt is tight and the crankshaft pulley is still positioned at the 90 ATDC mark 7 Using a 6mm hex key rotate the tensioner counterclockwise and align the centre of the indent on the tensioner pointer with the index wire ensuring that the pointer approaches the index wire from above If the pointer passes the wire release the tension completely and repeat the procedure 8 Ensuring that the pointer does not move tighten the tensioner bolt to 25 Nm Page 46 Lotus Service Notes Section XA 9 Using the crankshaft pulley bolt slowly turn the crankshaft 2 turns clockwise to check there is no valve piston contact and re align the timing marks without having to back up Check that the tensioner pointer is still correctly aligned with the index wire If not slacken the tensioner bolt until it is just possible to move the lever clockwise
366. he co axial cable ex tension and the amplifier lead are routed along the top of the engine bulkhead before connecting with the aerial base with a heat reflective sleeving used between the bulkhead and aerial to pro tect the leads from heat damage Aerial amplifier lead amp co axial extension lead Page 17 E Lotus Service Notes Section MN MN 6 BATTERY BATTERY CABLES amp 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 Antidote External flush with water Internal drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes flush with water for 15 minutes and get prompt medical attention 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 maintenance free battery is located in the front services compartment in the chassis well beneath the windscreen washer bottle 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 Battery retaining For access to the battery remove the washer Negative terminal reser
367. he engine management ECM opens a solenoid operated purge valve on the canister which allows a port on the throttle body downstream of the throttle valve to draw 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 i Full details of fuel pump testing fuel rail pressure regulator and fuel injectors are contained in engine management section EMN LH 2 FUEL FILLING Fuel Requirement Only UNLEADED fuel with a minimum octane rating of 95 RON Premium unleaded in U K should be used Unleaded fuel with an octane rating higher than 95 RON offers no additional benefit Note that the filler necks are restricted in size so that only the smaller diameter nozzle used on unleaded petrol pumps may be inserted The use of as little as one tankful of leaded fuel would cause irreparable contamination of the precious metal catalysts and 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 ensure that all cigarettes are extinguished and that no naked flames or other potential ignition sources are present Switch off the engine before refuelling Filler Cap The self locking filler cap is located in the right hand rear quarter p
368. he ignition circuit hot wiring Interruption of the vehicle battery power supply Page 19 RS Lotus Service Notes 340R When triggered the electronic siren will sound and the hazard warning lamps will flash 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 alarm when triggered disarm as described below Disarming the Alarm To disarm the alarm prior to entering the vehicle or if the alarm has been triggered press once the button on the transmitter key This command will be acknowledged by One flash of the hazard warning lamps Extinguishing of the alarm tell tale on the fascia top If the alarm had been triggered during the last armed period the alarm tell tale will light and off blink a code s for about 30 seconds to indicate which of the triggers was responsible 4 blink offs every 6 seconds engine lid or front access panels 8 blink offs every 6 seconds ignition input 1 blink off every 6 seconds microwave sensor This coding will be repeated each time the alarm is disarmed until the memory is cleared by pressing the transmitter button with the ignition switched on Intrusion Sensing A microwave sensor is mounted in the rear bulkhead electronics compartment and is able to detect substantial phys
369. he oil cooler air intake duct to the underside of the crash structure using the two fixings a the bottom of the towing eye strut Rifit the grille fixings Apply foam strips to each bottom flange of the duct Fit the oil cooler radiator to its mounting channel using the two thin head screws and position the assembly beneath the crash structure against the rear end of the intake duct Mark up and drill two M6 clearance Page 24 EN Lotus Service Notes Section XA holes in each side of the crash structure for the cooler mounting channel fixings and secure the channel Mark up and cut the two oil cooler hose routing holes in the front face of the body RH A post as shown in the diagram Remove the coin tray from the front of the driver s door sill With the aid of an assistant feed the two hoses through the body sill from front to back using access via the coin tray aperture and open rear end of the chassis rail First feed the right angle hose union through the sill baffle aperture before feeding through the straight union on the second hose Cooler hose holes in A post front face RH sill A post top surface cooler hoses 10 Use convoluted hose protection at the rear end of both hoses where they exit the sill area connect the hoses to the unions on the oil filter housing and tie strap to the adjacent water hose and or together as necessary Fit a grommet onto each hose and locate in the A post holes Feed the hoses th
370. he paint finish which covers the gel coat and in some instances can take as long as three months to appear Causes of gel cracks include 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 about in a luggage compartment Closing the bonnet or boot lid onto projecting objects e g luggage or tools Applying excessive force to parts attached to composite panels e g mirrors locks aerial etc action by vandals Incorrect jacking BM 3 BODYCARE The acrylic enamel paint finish of the Elan 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 Page 3 Lotus Service Notes Section BM 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 droppings highly acidic or alkaline they can chemically etch the paint Leaves contain tannic acid which can stain light finishes Washing Cauti
371. he radiator outlet hose bleed screw the system to 35 kPa 5 Ibf in and open the radiator hose bleed screw until a steady stream of coolant flows Tighten the bleed screw Radiator air bleed plug 5 Remove the pressure test equipment and top up the header tank to the cold level With the header tank cap removed start and run the engine at idle until the water temperature gauge reads 60 65 C In crease engine speed to 2000 rpm and observe the temperature gauge which should indicate 93 98 before dropping to 90 due to the action of the thermostat and the circulation of air pockets After a further rise and fall of indicated temperature re bleed at the radiator hose with the engine running 6 Continue to run the engine at 2000 rpm until the radiator return pipe at the engine feels hot at which time the header tank cap should be replaced Check that the radiator fan cuts in at 103 105 C and brings down the temperature to 90 95 before the cycle repeats 7 Stop the engine and allow to cool fully before topping up the header tank to the mark 4 RADIATOR amp COOLING FAN The aluminium cored radiator is mounted horizontally via four screws to a composite moulding which is itself secured to the top of the crash structure and also provides mounting points for the front clamshell A single electric cooling fan is secured directly to the underside of the radiator and is accessible only afte
372. he standard cap an additional safety valve is fitted into the breather pipe connecting the filler neck to the roll over valve This valve functions only in cases of extreme pressure change to prevent potential fuel tank damage Filler breather hose Roll over valve BRL d f Pressure relief valve To charcoal canister Page 18 ES Lotus Service Notes 340R 340 ELECTRICAL VEHICLE SECURITY The 340R uses a Meta security system as either an M36 T2 electronic immobiliser meeting Thatcham category 2 requirements or as an optional upgrade a full M99 T2 alarm system incorporating M23 cockpit intrusion sensing and a self powered siren which meets Thatcham 1 The Lucas 5AS security module used on the standard Elise is not fitted The Meta system operates as follows Keys amp Vehicle Security Alarm A single key operates the combined ignition switch steering lock with a second smaller key type for the fuel filler cap The head of each ignition key incorporates an electronic transmitter for operation of the engine immobiliser and security alarm system Duplicates of both keys are supplied with the new vehicle The key numbers are stamped on the keys themselves and should be recorded by the owner and kept with the vehicle documents to enable the dealer to have replacements made if necessary Standard Immobiliser In order to provide a measure of automatic vehicle security independent of
373. he trunking and a secondary filter mounted immediately after the resonator valve at entrance to the airbox When the vehicle is operated in a relatively clean environment the primary filter should be cleaned every A service and the secondary filter every service but where a dusty or smog laden atmosphere prevails more frequent servicing will be required dependent on the level of pollution When removing either filter take care not to contaminate the engine side of the duct or airbox with dirt Follow the filter manufacturer s cleaning instructions 1 Dislodge any large embedded dirt by tapping the filter gently Brush with a soft bristle brush to remove other dirt 2 Spray Pipercross foam air filter cleaner liberally onto the entire filter Let soak for 10 minutes 3 Never use other cleaning agents e g gasoline caustic strong detergents or solvents Never use steam cleaners or a high pressure car wash Doing so will invalidate the warranty 4 Rinse off the filter with low pressure tap water from the clean side to the dirty side This will remove dirt and not drive it into the filter 5 Always let excess water drain from the filter Let the filter dry naturally Never use compressed air open flame or hot air dryers 6 After cleaning the filter Pipercross Dirt Retention Additive DRA must be re applied Pipercross DRA is very efficient high tack polymer Never use motor oil diesel fuel ATF or WD40 7 Re install th
374. he upper ends of both legs sliding in a channel fixed to the bottom 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 A forward extension to the primary scissor leg carries a toothed sector which is engaged by a pinion on the window winder The glass is guided by front and rear felt lined alloy channels both of which are bolted to the door shell or beam with various adjustments provided to control the inward tilt of the glass its up height and the angle of the top edge Page 14 1998 1 E Lotus Service Notes Section BN Lift channel Stud carrier Lift mechanism Door glass Reaction channel b246 Re shim if Move reaction channel to necessary adjust front rear height Top fixing behind felt insert ur Move sideways Move fore aft Primary scissor Move sideways to to adjust lean to adjust pinch arm pivot adjust lean 1998 01 DS E Lotus Service Notes Section BN Door Glass Adjustment To adjust the door glass for optimum weather sealing and ease of operation 1 Remove the window winder handle and door trim panel Check that the top end of the toothed sector is fitted with an eccentric stop If not so fitted drill an M6 clearance hole through the sector in the position shown and fit a mesh friction washer between the eccentric and the sector Mesh washer 11100251 Eccentr
375. hed on with the illu 882345 73 4 mination dimming when the marker lamps are switched on to that level selected by the panel lights control see below Fuel Contents Display 22 The bottom left corner of the LCD panel Fuel contents Coolant temperature displays in the form of a bar graph the ap proximate proportion of fuel remaining in the 36 litre tank The bar graph displays in eight equal steps and to highlight a low fuel condi tion the display flashes when the level falls to the last eighth In order to ensure the vehicle is not stranded and to protect against the potentially damaging effects of fuel starvation it is strongly recommended to refuel at the first opportunity when the display flashes eet 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 40 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 fan switching on at approximately 104 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 whil
376. hole 85 mm Drill new 9 mm hole Electrical Connections 1 Disconnect battery negative cable first 2 Replace existing 8mm eyelets on battery positive cables with 6mm eyelets using crimp and solder tech niques 3 Fit new masterswitch relay into the battery well as shown in the illustration and attach the positive cables to one of the switch terminals 4 Fitthe new battery positive link cable A111M0109F from the other masterswitch terminal to the battery Prior to revised harness Unwrap the main harness at an area 175 mm from the fusebox to locate splice D where 4 white cables are joined Identity the thin white cable to the rear of the splice Cut this cable 100 mm from the splice and Page 27 eS Lotus Service Notes Section XA to one of the ends use splice crimp solder and heatshrink to connect the new green 1 0 mm wire leading to the new fuse holder to be attached to the side of the main fusebox and equipped with a 10A fuse Insert into the other cavity of the new fuseholder the terminated green wire from the new switchbox To the remaining end of the cut white cable splice crimp solder and heatshrink the unterminated green wire from the new switchbox With revised harness Release the main fusebox fixings remove fuse 7 and extract the green cable from cavity 7B Cut off the terminal from this cable and use splice crimp solder and heatshrink to connect with the unterminated green cable
377. horizontally This should not be confused with the water temperature gauge sender which is fitted in the same pipe but has a blue body and harness connector and is mounted vertically from below Low coolant temperature produces a high resistance whereas high temperature causes low resistance At normal running temperature the resistance will be approximately 300 400 ohms This data is also used to control the radiator fan which is switched on by the ECM at a rising coolant temperature of 102 C and switched off on falling temperature at 96 C Engine Coolant Temperature ECT sensor Brown Coolant temperature gauge sender Blue 80204 the ECM receives a signal voltage outside of the acceptable range default setting equating to 60 C will be substituted and the cooling fan energised To replace the sensor disconnect the harness plug and position a container to catch the escaping cool ant when the sensor is removed Unscrew the sensor from the junction pipe Clean the threads of the pipe and sensor before applying Teflon tape to the sensor thread and screwing into the pipe Tighten to6 Nm Refit the harness plug and top up with coolant see Cooling Section KF If the ECM detects a coolant sensor open circuit a default value of 60 C will be substituted and will be displayed on the Lotus Check scanner tool in Live Data Sensor faults may cause several symptoms including poor starting fast idle speed poor fuel consu
378. i fied quantity of oil to the compressor re assembly see section 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 cm Evaporator 30 cm Any major pipe or hose 10 Receiver drier 30 cm Approved Oils Use a refrigerant oil from only the following list Seiko SK 20 Unipart SK 20 Idemitsu SK 20 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 PH 9 Driv It Tensi The compressor is mounted at the front side of the engine and shares a multi rib drive belt with the alternator which is mounted above it A jockey wheel runs against the smooth back of the belt and provides a means of tension adjustment Clavis gauge T000T1398F Pulley clamp nut STE Tension adjuster screw GER 2000 04 Lotus Service Notes Section PH Tension should be checked using a Clavis frequency meter 000 1398 on only the lowermost belt run Specification 135 to 150 Hz Alternatively the belt is correctly adjusted when a force of 10 kg firm finger pressure at the centre of the lowermost belt run produces one way deflection of 9 10 mm To adjust the belt slacken the tensioner pulley nut and move the pulley using the adjuste
379. ial force is used Apply pressure only to the tulip or outer body of the joint Remove the R clip and clevis pin connecting the clutch slave cylinder to the release arm Remove the four bolts fixing the slave cylinder bracket to the transmission and support aside Release the two bolts securing the starter motor and dirt shield to the clutch housing Remove the shield and withdraw and support the starter motor taking care to protect the live starter motor lead from ground ing Remove the dirt shield from the top front of the clutch housing Disconnect the reverse light switch Disconnect the two gearchange cables from their transmission levers and release the cables from the abutment bracket Remove the air cleaner housing and mounting plate from the roll over bar brace Page 10 Lotus Service Notes Section FH 10 Support the weight of the transmission assembly before removing the LH engine transmission mounting and bracket 11 Remove the six bolts securing the clutch housing to the engine 2 bolts to the sump 1 bolt each side through the block lower wings 2 bolts securing the top of the clutch housing to the engine 12 Pushing the engine to the right and downwards at the flywheel end withdraw the transmission from the engine 13 Refit the transmission in the reverse order to removal with the following notes Check that the type of output shaft seals fitted are compatible with the drivesh
380. ic accurate individual wheel alignment equipment or a dedicated bump steer gauge must be used to measure the toe change for each rear wheel Lowering the joint height by 0 9 mm 1 shim washer will increase the toe in at 40 mm bump travel by approx 0 2 mm Refer to the graph below and select a shim stack to provide a toe change on bump travel to lie within the tolerance band Note that if the Uniball toe link is used the shim stack is distributed above and below the joint Tolerance band Bump 40 travel Displacement 1 from r de height mm 10 20 30 Droop travel 40 0 3 0 2 01 0 0 102 03 04 0 5 06 07 0 8 0 9 Increase in toe in from base setting mm 1 nt Page 19 Lotus Service Notes Section XA Base Setting Standard toe link with female threaded pivot balls 4x 1mm shim washers Standard toe link with integral stud ball joints 3 x 1 shim washers Uniball toe link 3 x 1 mm shim washer above joint When changing ride height the length of the toe link will need to be adjusted to maintain the specified rear toe setting but the base setting of the shim washers is the same for standard 140mm and race 100 110mm ride heights Note The standard toe link with female threaded pivot balls requires a very specific assembly configuration with different bolt lengths and washers used for different shim pack thicknesses Refer to sub section DE 4 for full details If a car with this joint type
381. ic stop B111U0084F Drill6mm clearance Existing hole hole 2 Establish whether the car is fitted with window upstop L brackets introduced in November 96 at VIN V 244 Note that it is not practicable to update earlier cars due to the requirement for captive fixings within the door beams Adjustable stops on door beam Legs welded to glass lift channel 1998 01 Lotus Service Notes Section BN 3 Apply Krytox P F P E lubricating fluid AQ82V6239S to the window guide channels and weatherstrips to reduce stiction judder and operating loads 4 With the window fully raised check the pressure of the front and rear glass edges against the A and B post seals The glass should make light contact with the whole length of the seal and allow easy opera tion of the glass up and down If necessary slacken the lower fixings of the front and rear guide channels to the bottom face of the door shell and reposition as required In extreme cases it may be necessary to adjust the shim pack between the rear guide upper fixing and the door beam to achieve the desired B post seal fit or to avoid overloading the door waist seal Before final tightening ensure that the pinch fore aft setting of the channels is correct to allow smooth operation without binding 5 With the soft top roof fitted and the window fully raised check the alignment of the glass top edge against the soft top roof and cant rail The whole of the glass
382. ical move ment within the cockpit and trigger the alarm The range and sensitivity of the intrusion sen sor may be adjusted if necessary by turning an adjuster screw on the unit If desired the alarm may be armed with out the intrusion sensor or battery interruption ciruits being active by With the alarm disarmed hold the trans mitter button pressed for a 4 second period INTRUSION SENSOR This will be acknowledged by 3 flashes of the hazard lamps and blinking of the alarm tell tale Note EM Intrusion sensing will automatically be reinstated the next time the alarm is armed not inhibit operation of the radar detector by placing bags or large objects against the cabin rear bulkhead Transmitter Key Battery Replacement The batteries for the key head transmitters should be renewed at six monthly intervals to Retaining ensure continuity of operation j To replace transmitter battery a Use a thin blade to prise apart the two halves of the transmitter key head and with 2 Batteries draw the battery b The transmitters are powered by a 3v long life lithium battery type CR2032 With normal use this should last between 3 and 5 years After opening the new battery packag ing touch only the sides of the battery and fit the battery into the key case with the positive side upwards as shown Press the battery case together Page 20 EC Lotus Service Notes 340R Naa Disconnecting t
383. icate sealing ring of new gasket with engine oil uoc Ne Fit timing plate 18G 1770 1 front or 18G 1770 2 rear Fit gasket align bolt holes Assemble clamp 18G 1770 to camshaft and VVC assembly fit camshaft gear bolt and washer to retain clamp Remove VVC housing and camshaft from vice Repeat above procedures for remaining housing gasket OVERHAUL 57 ENGINE Hydraulic control unit K16 VVC engines dismantling 12M3495A 58 Suitably identify each solenoid to its fitted position and note the angle at which it is positioned relative to the hydraulic control unit Remove nut from sleeve bolt remove and discard O ring Remove outer solenoid washer and O rings discard O rings Remove inner solenoid Remove spool valve remove and discard O ring from spool valve nut Remove and discard 4 O rings from spool valve Withdraw piston and rack assembly 9 12 3496 Remove and discard screw securing piston to rack remove and discard piston and seal assembly OVERHAUL Hydraulic control unit K16 VVC engines inspection 1 Check piston and spool valve bores in hydraulic control unit for scoring and corrosion replace control unit if scoring is evident 2 Check piston for scoring NOTE Light scoring and corrosion may be removed using grade 600 grade wet or dry paper which has been soaked in engine oil for
384. ich also controls the radiator fan and the temperature gauge are fitted in the cylinder head outlet elbow Coolant header tank KF 2 MAINTENANCE Under normal operating conditions the engine cooling system being a closed circuit should not require any topping up between services As a precau tion however every week the level of coolant in the engine cooling header tank should be checked The transluscent header tank is marked with both cold and hot level indicators The level of coolant will rise as the engine warms up and the cool ant expands and will fall again as it cools down Page 3 E Lotus Service Notes Section KF WARNING Do NOT remove the cap 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 A good quality mono ethylene g
385. ichever first occurs Any necessary repairs should be completed without delay cross X in the following table indicates an operation to be performed The corresponding box should be ticked v when the operation has been satisfactorily performed or the X circled if extra work and time is re quired 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 After Sales Service There is no charge to the vehicle owner for the labour content of the After Sales Service Only materials used will be charged 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 Odometer Reading Time Period Service Type 1 000 to 1 500 miles To be performed within 12 months of After Sales Service 1 500 to 2 500 km vehicle date of sale 9 000 miles 15 000 km Or 12 months since last service A 18 000 miles 30 000 km S 5 27 000 miles 45 000 km B 36 000 miles 60 000 km A 45 000 miles 75 000 km A 54 000 miles 90 000 km 63 000 miles 105 000 km A 72 000 miles 120 000 km A 81 000 miles 135 000 km B 90 000 miles 150 000 km A 99 000 miles 165 000 km A 108 000 miles 180 000 km 1998 03 Lotus Service Notes Section
386. ide of the windscreen with a 50 solution of water and isopropanol Allow to dry 6 Fit the interior mirror plinth to the inside of the windscreen The plinth is supplied as part of a kit which includes adhesive GZH WARNING Contains trichloroethanes and acrylic acid derivatives Refer to precautions on product packaging Thoroughly clean bonding face of mirror plinth and corresponding area on inside surface of wind screen using steel wool Bend and crack the primer vial to allow the primer to saturate the felt tip Apply the primer to the bonding surface on both the plinth and windscreen Allow five minutes for the primer to dry Apply a thin coat of adhesive to the bonding surface of the mirror plinth Position the plinth on the windscreen with the dimple lowermost and hold in place for 2 to 3 minutes Allow at least 10 minutes curing time before fitting the mirror Windscreen top edge end Screen centreline Obscuration _ Mirror position on LHD offset to right Mirror position on RHD offset to left 7 Clean the whole of the inside surface of the obscuration band and the laminated edge of the glass with the wipe cleaner Similarly clean the whole of the bonding surface on the windscreen frame 8 Fitthe rubber edge finisher around the top and sides of the windscreen with a 30 mm overhang at each end 9 Apply a 25 mm wide band of Betaprime 8 mm around the outside of the glass Simila
387. idity The panels 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 major panels are manufactured by the VARI Vacuum Assisted Resin Injection process using a low profile resin and are of a nominal 2 mm thick ness The windscreen frame incorporates foam beams to create closed box sections for optimum strength and 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 BM 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 thickn
388. iency will increase significantly as the brakes bed in and for cars with aluminium discs as a deposit of the brake pad materia builds on the part ceramic discs characterised by a dull grey band around the rubbing surface 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 JH 2 BRAKE FLUID CHECK amp CHANGE Before checking the brake fluid level ensure that the car is parked on a level surface and remove the front bonnet The level of fluid in the reservoir may be inspected without disturbing the filler cap and should lie between the MIN and MAX marks moulded on the transluscent 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 fascia mounted tell tale lamp if the level becomes dangerously low 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 An internal baffle divides the reservoir into two compartments with the front section supplying the front brake circuit and the rear section the rear brakes in addition to via a short linking hose the clutch master cylinder
389. if a thread is damaged Thread inserts Helicoil are not acceptable 78 OVERHAUL CRANKSHAFT MAIN amp BIG END BEARINGS Crankshaft end float checking CAUTION Crankshaft end float must be checked and recorded prior to removing cylinder head 1 Check crankshaft end float using a DTI Carefully lever against flywheel and press crankshaft away from DTI zero DTI and push crankshaft towards DTI Crankshaft end float 0 10 to 0 25 mm Service limit 0 34 mm 2 Record end float figure obtained ENGINE Fosse Crankshaft main and big end bearings remove 1 Remove flywheel 2 Remove tool 18G 1571 3 Remove and discard camshaft timing belt 4 Withdraw dipstick 5 Remove 3 screws and dipstick tube discard gasket 6 Remove cylinder head assembly CAUTION Ensure cylinder liner retainer A clamps 18G 1736 are fitted 7 Remove oil pump 8 Using assistance position cylinder block cylinder head face down on 2 wooden blocks CAUTION Ensure that wooden blocks are of sufficient thickness to prevent cylinder liner clamps contacting workbench BRM 3481 9 Remove bolt and anti beaming bracket where fitted 10 Remove 3 M6 x 35 bolts and anti beaming bracket support discard bolts OVERHAUL 79 ENGINE Pressed steel sump 11 Remove and discard 14 bolts securing sump to bearing ladder 11 bolts if anti beaming bracket support is removed 12 Remove sump 13 R
390. ig end bearings and caps are to be fitted 6 Fit big end bearings OVERHAUL 97 DATA Oil pump Outer rotor to housing clearance 0 28 to 0 36 mm Inner rotor tip clearance 0 05 to 0 13 mm Rotor end 0 02 to 0 06 mm Relief valve spring free length 38 9 mm Cooling system Thermostat starts 88 Nominal setting 85 10 91 C Thermostat fully open 100 Camshafts Camshaft end float and K16 Non VVC engines 0 06 to 0 19 mm 0 3 mm Camshaft end float K16 VVC engines IO Siete LEE 0 03 to 0 15 4 0 25 Exhaust 0 06 to 0 19 mm Service limit 0 3mm Camshaft bearing clearance K8 and K16 Non VVC engines 0 060 to 0 094 mm 0 15 Camshaft bearing clearance K16 VVC engines Inlet 25 mm diameter journals 0 025 to 0 060 0 1 mm Inlet 40 mm diameter journals 0 03 to 0 07 mm Service limit 0 1 mm Exhaust o ER x 0 060 to 0 094 mm Service limit
391. ignition has been turned off The immobilised state will be indicated by the alarm tell tale on the fascia top ahead of the instruments blinking once every two seconds To mobilise the engine press once the button on the transmitter key head with ignition either on or off Mobilisation will be acknowledged by the tell tale being extinguished Arming the Alarm Remove the ignition key and check that the engine lid and front access panels are closed Press the transmitter button for about two seconds This command will be acknowledged by Two flashes of the hazard warning lamps The tell tale on the fascia top lighting and blinking off once a second After a set up period of 25 seconds has elapsed the tell tale will go out and blink on once a second 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 the engine lid or a front access panel is not fully closed four beeps will be heard as warning if still open after 25 seconds the alarm will be armed with that switch excluded from the circuit After arming the system a period of at least 25 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 Opening the engine lid or front access panel Movement detected within the cockpit Energising t
392. il cooler duct Mounting bracket Front undertray Page 23 Lotus Service Notes Section XA Fitting Procedure 1 Air inlet holes in crash structure floor 83 mm diameter holes Cooler hose holes in crash structure RH side Replace the oil filter housing on the engine with the new housing which incorporates feed and return ports for the oil cooler hoses Transfer the oil filter canister Fit the new blanking plug into the tapped hole in the top of the housing Using a thread sealant screw the new adaptor elbow into the tapped hole on the underside of the housing and from the old filter housing transfer the brown bodied oil pressure switch into the elbow Note i If a new VHPD engine is being fitted tie back the unused black coloured harness connector oil pressure gauge transducer ii If the old oil pressure switch is the later post Jan 98 parallel thread type the earlier type tapered thread switch must be ordered and fitted 111 60995 Remove the front clamshell and undertray Mark up and cut the air inlet holes in the floor of the crash structure as shown in the diagram and also the hose routing holes in the RH side of the structure Fit grommets into the hose routing holes Towing strut fixing holes 30 mm holes for cooler hoses 6 5 mm holes oil cooler mounting bracket Undertray front fixing Remove the lower centre three fasteners for the radiator air intake grille and fit t
393. ill be indicated by the immobiliser tell tale mounted ahead of the gear lever blinking once every two seconds To mobilise the engine press once the button on the transmitter key head with ignition either on or off Mobilisation will be acknowledged by the tell tale being extinguished Upgraded Security System For enhanced protection from theft and vandal damage the EXIGE may be specified factory built with a Meta vehicle security system which incorporates the following features Ingress protection using sensing switches on the front access panels and engine lid Selectable cockpit intrusion sensing using a microwave sensor Automatic passive engine immobilisation to prevent the engine from being started Self powered siren to maintain protection if the vehicle battery is disconnected Dynamic coding of the transmitter keys Each time the transmitters used the operating frequency is randomly changed to guard against the possibility of code copying Passive Immobilisation In order to provide a measure of automatic vehicle security independent of any driver initiative the Meta M36 T2 immobiliser will passively immobilise the engine s cranking and running circuits about 20 seconds after the ignition has been turned off The immobilised state will be indicated by the alarm tell tale mounted ahead of the gear lever blinking once every two seconds To mobilise the engine press once the button on the transmitter
394. illar bolt supplied with the replacement belt to adjust tension 1 Clean timing gears coolant pump drive gear and tensioner pulley CAUTION If the sintered gears have been N subjected to prolonged oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the belt 18G 1570 M124929 NOTE VVC camshaft gear timing marks are shown the inset the illustration 2 Check correct alignment of camshaft gear timing marks fit camshaft gear locking tool 18G 1570 AN NM M124962 3 Check that crankshaft gear timing marks are aligned with flange on oil pump 90 BTDC Flywheel not fitted with a reluctor ring 4 Fit flywheel locking too 18G 1571 secure with 2 bolts OVERHAUL 7 ENGINE Flywheel fitted with a reluctor ring 1861674 124937 5 Fit flywheel locking tool 18G 1674 tighten bolt CAUTION Ensure tooth on tool 18G 1674 engages with teeth on flywheel not the reluctor ring 6 VVC engines Fit tensioner spring and pillar bolt supplied with replacement timing belt connect spring to tensioner backplate and pillar bolt CAUTION Ensure spring is the correct type for the engine being worked on Non VVC engines Spring is fitted with a sleeve VVC engines Spring is not
395. imilar manner to the Elise but uses sill exten sions behind the front wheelarches to which the clamshell rear ends are attached and a seperate screwed on splitter panel around the clamshell front lower edge Clamshell gutter fixings A Splitter panel SX LA to undershield To A post top bracket Fixings to sill extension 2000 03 icd Se To remove 1 Remove both front road wheels and wheelarch liners 2 At each side remove the 8 fixing securing the clamshell to the sill front extension panel 3 Remove the single M8 screw securing each top rear corner of the clamshell to a bracket at the top of the post 4 Removethe four fixings in the bonnet gutter one at each rear end and one in each front corner The rear pair are also used as adjustable mounts for the bonnet closing buffers and use 8 captive fixings in the screen frame buttresses The front pair use M8 captive fixings in the radiator mounting panel Take note of the shim stacks fitted at each of the fixing points 5 From beneath the nose remove the five screws securing the rear edge of the splitter panel to the alloy undershield 6 Disconnect the clamshell wiring harness at the driver s side of the front compartment and lift the clamshell from the car Note any spacing washers or shims fitted at any fixing point 7 Refitthe clamshell in reverse order to removal taking care to retain any spacer washers i
396. in Pirelli Zero 205 50 rear tyres There are variations in the specification of Pirelli tyres with this designation dependent on where and when they were manufactured Lotus fitment should be either i Made in Italy moulded on inside tyre wall or ii Made in Great Britain moulded on inside tyre wall and with a DOT date of week 35 year 1997 coded as 357 or later see below Page 2 GS Lotus Section Lotus Service Notes Section Note a The U K built tyre was introduced on production at VIN V 1700 approx b Italian and U K variations of rear tyre should not be mixed the same axle The DOT code is moulded on the outside wall with only the last number group relevant to this issue Note that the three digits represent a date code as explained above and not an ordi nary sequential number Pirelli Zero 225 45 rear tyres There are variations in the specification of this Pirelli tyre dependent on when it was manufactured For the Elise use only tyres with DOT date code of week 35 of year 98 coded as 358 or later Alternative Service Fitment As an alternative to Pirelli tyres a complete vehicle set of Michelin Pilot SX GT tyres may be fitted in service using the wider rear tyre specification It is not recommended to mix Pirelli and Michelin tyres on the same vehicle Type Size front rear Pressure cold front rear WINTER TYRES Type Size front
397. in accordance with the manufacturer s instructions 2 Standard R134a quick 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 2000 04 iiio E Lotus Service Notes Section PH 7 REFRIGERANT PIPEW TIONS 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 equip ment 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
398. ines that plugs 1 amp 2 receive positive sparks and plugs 3 amp 4 negative sparks It is important to note that if it is necessary to run or crank an engine with one or more plug leads disconnected either the coil low tension must be disconnected or provision for the spark energy to be dissi pated must be made e g fitting a loose grounded spark plug to the lead otherwise the electrical stess produced will cause deterioration of the H T coil and or ECM Each coil has a primary winding resistance of 0 71 0 81 ohms at 20 C and a secondary winding resist ance of approx 10 5 kilohms Note that the coils can tolerate a certain amount of water spray but contamination with anti freeze solu tion can result in penetration of the insulation with consequent danger of current leakage and misfire Any coil suspected of being contaminated should be renewed 2000 IO Lotus Service Notes Section FH TRANSMISSION SECTION FH M111 ELISE Sub Section Page Introduction FH 1 2 Gearchange Mechanism FH 2 2 Lubrication FH 3 6 Driveshafts FH 4 6 Transmission Replacement FH 5 10 Transmission Overhaul amp Special Tools FH 6 11 Paae 1 Lotus Service Notes Section FH FH 1 INTRODUCTION The transmission assembly is an end on type mounted on the left hand end of the engine unit and comprises of the clutch housing five speed gearbox final drive gears and differential The unit is supplied by Rover and is designa
399. ing a roller CAUTION To avoid contamination assembly should be completed immediately after application of sealant Do not use RTV or any sealant other than specified OVERHAUL 89 ENGINE 26 27 28 29 A 30 31 90 12M1784 Screw alignment pins 18G 1744 into hol s shown Caretully lower sump over pins and on to bearing ladder Fit 2 bolts into holes shown tighten to 4 Nm Fit 10 bolts into remaining holes lightly tighten ail bolts CAUTION Ensure 2 8 x 60 bolts are in original fitted positions Remove alignment pins 18G 1744 fit and lightly tighten remaining 2 bolts Using a straight edge check that machined face of sump flange is level with rear face ol cylinder block Check in 3 positions and if necessary tap sump gently to re position it OVERHAUL 12M1783 32 Using sequence shown tighten 14 bolts to M8 x 25 25 Nm M8 x 60 30 Nm ENGINE Hesse All engines 33 Apply a 1 5 mm continuous bead of sealant Part No GAC 8000 to replacement oil seal as shown CAUTION Do not apply oil or grease to any part of oil seal or running surface of crankshaft Seal must be fitted immediately after applying sealant A 18G 1 574 7 SS 35 2 Zl 34948 34 Position oil seal to cylinder block 35 Fit oil seal replacer tool 18G 1574 to crankshaft retain tool using 3 slave bolts 36 Tighten bolts to pr
400. ing column The left hand lever switch 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 le ver moved back towards the wheel The main beam tell tale lamp in the instrument panel lights when main is operating Instrument illumination button Cigarette lighter Main beam Left turn Dip beam Flash 01522 13 E Lotus Service Notes Section MN Note that on cars equipped with the optional driving lamps mounted in the radiator air intake the bonnet mounted headlamp main beams are supplemented by the two driving lamp 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 pressing the switch up or down only lightly will allow it to return under spring action upon release 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
401. ing is scored or clearances are excessive 16 OVERHAUL ENGINE Fosse Jii pressure relief valve 12M3531 Unscrew plug discard sealing washer 2 Remove spring and relief valve sleeve assembly 3 Check that valve sleeve slides freely in bore and that bore and sieeve are free from scoring and corrosion NOTE Light corrosion may be removed A using grade 600 emery cloth soaked in engine oil 4 Check free length of spring Spring free length 38 9 mm Replace relief valve as an assembly if scoring of plunger is evident or free length of spring is less than specified Replace oil pump if relief valve bore is scored 5 Remove all traces of Loctite from plug and threads in relief valve bore j CAUTION Do not use a tap 6 Apply Loctite 577 to threads of plug 7 Fit plug use a new sealing washer Oit pump assembling 1 Ensure outer rotor identitication marking faces outward 2 Lubricate pump rotors with engine oil 3 Lubricate a new cover plate seal with engine oil 4 Fit cover plate seal and cover plate 5 Apply Loctite 222 to cover plate securing screws fit and tighten screws 6 Check that pump rotates freely OVERHAUL ENGINE Oil pump refit 1 Clean oil pump 2 Using gasket removal spray and a plastic scraper remove all traces of gasket from oil pump Clean oil seal running surface on crankshaft Fita new dry oil pump gasket 5 Turn oil pump ro
402. ing male cone in the gear chosen This synchronizes the speeds of the synchronizer hub and gear The synchronizer sleeve then engages the gear and by means of a spring ring teeth extensions on the synchronizer sleeve and detents in the selector shaft holds the selected gear in engagement Torque is transmitted from the input shaft through the selected gear to the output shaft pinion and final drive gear to the drive shafts REVISED 12 97 DESCRIPTION AND OPERATION 5 MANUAL GEARBOX OPERATION TORSEN DIFFERENTIAL 37M0181 Torsen differential Type A Serial number prefixes K4BX and K7BSUT Helical side gear Element gear assembly worm and spur gears Journal pin Thrust washer and spacing washer Two thrust washers and needle roller bearing _ __________ __ _ ____ E 6 DESCRIPTION AND OPERATION 37M0697 Torsen differential Type B Seria number prefixes C6FTUT W4DTUT CeDTUT and C6DTUTH 1 Helical side gear 2 Element gear assembly helical gears 3 Friction washers 4 Thrust washers Unlike a conventional limited slip differential the torque sensing differential does not rely on the locking value of friction discs but by the friction produced by the teeth of the two helical side gears splined to the drive shafts meshing with the gears of the element gear assemblies On Type A differentials additional locking values are generated by the
403. ing on the driveshaft This action will cause the joint to become disassembled and may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive axial force is used Apply pressure only to the tulip or outer body of the joint Remove the intake hose between air cleaner housing and engine Pull out the button retaining the housing to the mounting bracket and withdraw the cleaner housing from its mounting grommets Re lease the mounting bracket from the roll over bar strut Remove the R clip and clevis pin connecting the clutch slave cylinder to the release arm Remove the four bolts fixing the slave cylinder bracket to the transmission and support aside 1998 2 Page 9 10 11 12 Lotus Service Notes Section QF Release the two bolts securing the starter motor and dirt shield to the clutch housing Remove the shield and withdraw and support the starter motor taking care to protect the live starter motor lead from ground ing Remove the dirt shield from the top front of the clutch housing Disconnect the reverse light switch and speedo drive cable Disconnect the two gearchange cables from their transmission levers and release the cables from the abutment bracket Support the weight of the transmission assembly before removing the LH engine transmission mounting and bracket Re
404. ing the spark plugs using a 16 mm 5 8 A F spark plug socket spanner Take precautions to prevent debris falling into the open plug holes Check the electrode gap of each new plug and reset if necessary to 0 9mm 0 035 in Fit the plugs taking care not to cross thread and tighten to 25 Nm Refit the plug leads pressing firmly and checking that they are correctly located in their routing clips Secure the access cover Spark plug Plug lead amp access cover connector Spark plug Page 4 Lotus Service Notes Section EE EE 3 ENGINE REMOVAL REPLACEMENT The engine may be removed from above with or without the rear clamshell in position It is recom mended to remove the clamshell for improved access and to reduce the possibility of paint damage If the clamshell is left situ the luggage comopartment divider panel if fitted must be removed in order to allow the power unit to be turned thro 90 as it is withdrawn The operation is best performed on a wheel free lift as in order for the driveshafts to be withdrawn the upper ball joints must by released from the hub carriers 1 10 Fuel Pressure Relief Procedure The fuel line between pump and injector rail and the injector rail itself contain pressurised fuel both when the engine is running and after switching off The following procedure must be used before disconnecting the fuel feed line Pull out the fuel pump 104A fuse to the rear of the
405. inimum z 0 20 mm New run out 0 8 mm max Service limit 1 0 mm max Renew the plate if any damage is detected if outside service limits If there were symptoms of clutch judder the friction plate should be replaced as a precaution regardless of inspection results 16 Inspect the surface of the pressure plate for excessive wear or scoring and replace if in any doubt If there were symptoms of clutch judder or the cover is accidentally dropped the clutch cover assembly should be replaced as a precaution regardless of inspection results 17 Check the surface condition and run out of the flywheel friction surface see section ED 14 and replace the flywheel if necessary 18 Withdraw the release bearing and examine for signs of wear damage or roughness and replace if in doubt 19 Examine the condition of the clutch release fork pivot shaft bushes and oil seal see transmission repair section and replace components as necessary Re fitment of clutch assembly 20 Smear the splines of the friction plate with molybdenum disulphide grease and fit against the flywheel with the FLYWHEEL SIDE marking towards the flywheel Fit the clutch cover over the friction plate and locate on the flywheel dowels 21 Fitclutch alignment mandrel T000T 1483 to centralise the friction plate and fit the clutch cover retaining screws finger tight Using a diagonal sequence progres sively tighten the cover screws and monitor the free t
406. ion System EMN 17 24 2000 01 Page 1 EG Lotus Service Notes Section EMN me 2000 01 E Lotus Service Notes Section EMN EMN 1 INTRODUCTION 1 Fuel pump 14 angle sensor VVC only 2 Engine coolant temperature ECT sensor 15 Idle air control IAC valve 3 Water temperature gauge sender vertical 16 Throttle postion TP sensor 4 Crankshaft position sensor 17 Throttle body 5 Oxygen sensor 18 Relay module 6 intake air temperature IAT sensor 19 Data link connector DLC 7 Oil temperature sensor VVC only 20 Electronic control module ECM 8 VVC control solenoids 21 Inertia switch 9 Fuel injector 22 Vehicle speed sensor 10 Fuel pressure regulator valve 23 Fuel filter 11 Fuel rail 24 Distributor std only 12 Manifold air pressure MAP sensor VVC only 25 Evaporative emissions canister 13 Ignition coil std and VVC shown The 1 8 K Series engine fitted to the Elise is equipped with a Modular Engine Management System MEMS version 1 9 for the standard engine and version 2J for the VVC engine abbreviated to 1 9 or MEMS 2J Both versions use a single electronic control module ECM to control both the fuel injection and ignition systems and base the control strategy on engine speed air density measurement Engine speed data is derived from a flywheel sensor with air density calculated from manifold air pressure and manifold air temperature signals The engine
407. irclip 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 Special tool 000 1390 9 A special tool T000T1390 is available to protect the seal during driveshaft fitment and should always be used with the more vulnerable early type seal see above To use the tool Check first that the tool is clean and undamaged before fully inserting into the oil seal Check that the split joint in the tool is butted correctly Carefully insert the driveshaft through the seal protector until it engages in the splines of the differential output gear Remove the protector tool by pull ing over the shaft Page 8 10 11 12 amp Lotus Service Notes Section Press the joint into the differential gear splines unti a click indicates that the circlip has engaged in its location Pull on the body of the joint to check security Fit the outer end of the shaft into the hub and retain with the nut Refit the top ball joint plinth to the hub carrier with the camber adjustment shim pack in position and tighten the two socket head bolts to 45 Nm Apply the parking brake and tighten the driveshaft nut to 220 Nm Tighten the toe link to hub carrier pivot bolt to 45 Nm Refit the wheel
408. is found to require more than 5 shim washers to produce the required charac teristic both outboard ball joints should be changed for the integral stud type or Uniball links fitted EES 1999 01 Lotus Service Notes Section XA XA 9 FRONT HUB CLAMP BOLT SET A111C0137S This set is applicable only to cars built before Sept 1997 approx VIN W 1830 with M12 front hub clamp bolts If the car is to be used in a competition environment with the associated high level of chassis loading it is recommended to replace the front hub bearing M12 clamp bolts with an M16 clamp bolt set including thrust washers which allows a substantial increase in the clamping force applied to the inner bearing races Cars from the above change point have been factory built with the M16 bolt set Kit Contents Part no Qty Front Hub Clamp Bolt Set A111C0137S 1 comprising Bolt M16 x 100 bearing clamp A111W2185F 2 Nut M16 Nyloc bearing clamp bolt A111W3159F 2 Thrust Washer outer A111C0117F 2 Thrust Washer inner A111C0118F 2 Dust Shield front wheel bearing B111C0076F 2 Washer M16x30x2 A111W4171F 2 The M16 clamp bolt set is a direct replacement for the M12 set and it is recommended that at the time of fitting the hub is removed from the bearing and the condition of the hub spigot carefully examined If any signs of bearing inner race movement on the hub are evident the hub and bearing should be renewed and assem bled with the new bolt set In
409. is mounted on the intake plenum and controls an air passage which by passes the throttle valve When the pintle of the valve is fully extended the passage is closed off for a minimum idle speed but as the ECM commands the IAC stepper motor to withdraw the pintle a progressively greater amount of air is allowed to by pass the throttle In this way the ECM is able to control engine idle speed independently of the throttle butterfly NOTE The closed setting of the throttle valve is preset during manufacture and must NOT be ad justed During cold starts the IAC is opened to provide a raised idle speed dependent on coolant temperature with a gradual decay as the engine warms to normal operating temperature The ECM also uses the fast response of ignition timing variation to maintain idle stabilisation such that at idle the ignition timing will be constantly changing When loads are placed onto or removed from the engine the ECM senses the change in engine speed and uses both ignition timing and IAC position to control idle speed The position of the idle air contro valve should be within the range of 20 to 40 steps as displayed by a Lotus Check scanner when the engine is idling at normal engine temperature This ensures that the idle ari control valve is able to supply varying amounts of by pass air to compensate for all loads and temperature conditions If outside of this range there is likely to be a mechanical fault such as an intake ma
410. isconnect the blender flap control cable from the flap lever and abutment and unplug the fan harness connector 5 Release the single fixing securing a bracket on the top rear of the unit to the chassis and withdraw the unit from the chassis climate chamber 6 Before refitting the unit in reverse order to the above first check that the battery earth cable is correctly secured to the chassis earth point at the left hand side of the climate chamber and on LHD cars is correctly routed across the chamber floor to the passenger side front corner Also check that the battery breather pipe is routed through the aperture at the bottom centre rear of the chamber Single fixing Heater unit 2000 04 dom E Lotus Service Notes Section PH AIC EXIGE CIRCUIT COOLING FAN 2 CAVA cava 252m 25 07 00 EC REQ O P 2000 04 Lotus Service Notes Section QF CLUTCH SECTION QF M111 ELISE Sub Section Page General Description OF 1 2 Adjustment OF 2 3 Hydraulic Release System OF 3 4 Clutch Assembly OF A 9 Dana 4 Section QF Lotus Service Notes edid ajqixej4 jepad uoinj2 4 5 uoinj2 J pUIJ 2 une Bunesado ayesg Ajquiasse 1 0 2 Paseys jepad 1998 02 mg Page 2 CS Lotus Service Notes Section QF
411. ise 340R January 00 VIN Y 0004 to 0009 9640 onwards Limited edition of 340 Extreme lightweight version of the Elise based on modified standard chassis fitted with minimalist bodywork and a detuned road going version of the VHPD powertrain See 340R supple ment for full specification 2000 03 Lotus Service Notes introduction Sport 160 February 00 SVA VIN Y 00601 to 00650 WVTA VIN Y 0651 onwards First 50 cars with Single Vehicle Approval Subsequent cars Whole Vehicle Type Approved High per formance derivative based on 111S specification with 160 PS fixed valve timing engine WVTA versions require airbox modification and sport exhaust fitment for full power release Other features include new engine controller sport suspension race wheels plinth mounted rear aerofoil Alcantara trimmed seats and steering wheel pad body decals Exige July 00 VIN Y 0001 Character 13 8 model specific serial number sequence Road going version of the Elise race series car with 178 bhp 340R engine close ratio transmission sport suspension and larger 12 spoke black finish wheels 16x7 amp 17x8 5 with Yokohama A039 tyres Front and rear clamshells styled as race car with piller mounted rear aerofoil Clear polycarbonate rear tailgate with air ducting linked to roof mounted air intake duct Optional Alcantara sports seats and 340R harnesses Meta security system Roof duct mounted radio aerial 2000
412. istons for distortion and cracks Measure and record piston diameter at right angle to gudgeon pin and 8 mm from bottom of skirt Check piston diameter with figures given Measure and record piston diameter in line with gudgeon pin hole and 8 mm bottom of skirt Check piston ovality with figures given Repeat above procedures for remaining pistons K8 and K16 1 1 and 1 4 Grade A 74 940 to 74 955 mm Grade B 74 956 to 74 970 mm Maximum ovality 0 3 mm K16 1 6 and 1 8 Grade A 79 975 to 79 990 mm Grade B 79 991 to 80 005 mm Maximum ovality 0 3 mm Service pistons are grade A and B e NOTE Piston grades A or B are stamped on crown of piston OVERHAUL 93 ENGINE Piston to cylinder liner bore clearance checking Piston rings refit CAUTION Ensure that piston rings are fitted to piston for the cylinder bore in which they were checked 1 Fit oil control spring 2 With TOP or identification markings to top of piston use an expander to fit piston rings in sequence oil control 2nd and top compression 1 12 3638 2 1 Starting with number 1 piston invert piston and connecting rod and with word FRONT or arrow 7 SS on piston crown facing towards REAR of B A cylinder block insert piston in cylinder liner 12M1811 2 Pasition piston with bottom of skirt 30 mm from top of cylinder block 3 Using feeler gauges measure and record clearanc
413. it the original camber adjustment shimpack and distribute the shims as noted on re moval Lubricate the ends of the damper top eye bush with rubber grease Press the brake pedal to reposition the pads before driving the car 15 The Service Schedule specifies that the security of the front and rear suspension is checked at each service This operation requires that all the principal suspension pivot bolts are torque checked noting the following points Where 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 lost Remove the bolt completely clean off all old adhesive using a wire brush and acetone and apply new adhesive as speci fied 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 Nm Upper and lower wishbone pivot bolts 45 Upper swivel joint t
414. iters and the adjustment of the rack pressure pad Steering rack Steel reinforcement channel bonded assembly M10 fixing bolt 8 fixing bolt Pop rivet Chassis crossmember 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 Frominside 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 Frominside 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 Page 9 Lotus Service Notes Section 5 Onre assembly 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 HE 2 6 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 7 Fitthe lower u j pinch bolt and tighten to 35 Nm 8 Fitthe track rod ends into the steering arms and tighten the nuts to 30 Nm 9 Check and adjust the
415. ition If the belt exhibits any evidence of physical damage cracking fraying perishing abrasion or contamination it should be replaced Note that some super ficial cracking of the belt rib rubber covering is normal and need not cause concern but isolated deeper cracks affecting the underlying belt structure require the belt to be replaced In the case of oil contamination the cause must be identified and rectified and each of the pulleys must be thoroughly degreased before the new belt is fitted Pivot bolt A To replace the belt Slacken the alternator pivot bolt A Slacken the clamping bolt B securing the alternator to the slotted strap mE Turn the adjuster bolt C in the end of SS the slotted strap to allow the alternator 2 to be swung towards the engine unhook the belt from the pulleys Fit the new belt over the two pulleys 7 4 4 ensuring it is correctly seated in the CAE lt a grooves and tension the belt such that 2 Kr moderate finger pressure at the centre A LA 29 ZR CC of a belt run produces a one way deflec tion of 6 mm Tighten the clamping and pivot bolts Clamp bolt B Adjuster boit C Sparking Plugs Renew the sparking plugs in accordance with the Maintenance Schedule Remove the two screws securing the spark plug access cover and pull off the HT lead from each spark plug Use an airline or vacuum cleaner to re move any loose dirt from the plug wells be fore unscrew
416. ition connect plug leads 7 Fit HT lead cover tighten screws to 5 Nm OVERHAUL 77 ENGINE CYLINDER HEAD BOLTS INSPECTION RIA LU NM 1 Retain bolts in fitted order 2 Wash all bolts wipe dry and lightly oil threads Cylinder head bolts may be re used provided they pass one of the following tests Test with cylinder head removed 1 Caretully enter cylinder head bolts in their original fitted location DO NOT DROP Screw each bolt by hand into oil rail CAUTION It will be necessary to temporarily remove cylinder liner retainer clamps 18G 1736 in order to test the bolt used with the retainer clamp Retainer clamps should only be removed one at a time and replaced immediately bolt test is completed Take great care not to rotate crankshaft or disturb cylinder liners whilst clamps are removed 2463 2 Measure distance from cylinder block face to under bolt head A in illustration 97 mm or less bolt may be re used Over 97 mm new bolt must be used Test with oil rail removed 1 Ensuring cylinder head bolts are in their original fitted location screw each bolt by hand into oil rail 2 If full length of thread is engaged bolt may be re used 3 If full length of thread is not engaged measure distance from top face of oil rail to under bolt head B in illustration 378 mm or less bolt may be re used Over 378 mm new bolt must be used CAUTION A new oil rail must be fitted
417. itre 3 7 imp pt 36 4 litre 8 0 imp gall 8 0 litre 1 8 imp gall Independent Upper and lower wishbone co axial coil spring telescopic damper unit anti roll bar 112 mm below front end of chassis siderail 122 mm below rear end of chassis siderail 12 nominal 3 8 0 2 max side side 0 2 0 5 0 1 0 25 max side side 0 27 0 1 mm toe out overall 0 1 mm 0 Page 3 Rear Suspension Type Ride height for geometry check Camber Alignment Engine Type designation Cylinder configuration Capacity Bore Stroke Compression ratio Firing order Spark plugs Spark plug gap Maximum engine speed Fuel requirement Fuel system Valve clearances cold inlet exhaust Max power Max torque Page 4 front rear Independent Upper and lower wishbone Coe coil spring telescopic damper 112 mm below front end of chassis siderail 122 mm below rear end of chassis siderail 24 0 2 max side side 0 2 1 2 mm toe in each side 0 2 mm 0 max side side 0 2 mm K16 in line 4 1796 70 71 80 00 3 150 89 30 mm 3 516 11 0 1 1 3 4 2 Champion RC6 6YCC 0 85 0 1 mm 0 033 in 7800 rpm Unleaded 95 RON min Multi point fully sequential fuel injection with Lotus controller 0 25 mm 0 010 in 0 30 mm 0 012 in 132 5 kW 178 bhp 7 800 rpm 172 Nm 127 Ibf ft 6 750 rpm 2000 03 cng Lotus Service Notes
418. itted Bolt coolant pump Locating dowel Thermostat housing plastic ring Seal thermostat Thermostat Cover plastic Screw O ring Coolant rail Screw coolant rail Vent screw if fitted Sealing washer Oylinder block Oylinder liner Ring dowel Piston and connecting rod assembly Big end bearing cap Connecting rod bolt Big end bearing shells Top compression ring 2nd compression ring control ring Crankshaft Ring dowel 39 Main bearing sheils Plain in block Nos 1 and 5 Grooved in block Nos 2 3 and 4 Plain in bearing ladder Thrust washers Crankshaft rear oil seal Flywheel assembly Flywheel bolt Patchlok Bearing ladder Bolt bearing ladder Bolt bearing ladder Ring dowel Oil rail Stud rail Nut oil rail Oil filter adapter Gasket Bolt Oil pressure switch Sealing washer Oil temperature sensor if fitted Sealing washer Oil filter element Pressed steel sump Gasket Sump bolt M6 Patchlok Drain plug Sealing washer Alloy sump Sump bolt M8 x 25 Sump bolt M8 x 60 Drain plug Sealing washer Oil suction pipe Screw oil suction pipe O ring Blanking plate Screw blanking plate DESCRIPTION AND OPERATION 3 GINE ME a ae E 33 amp T Che 2 o ANQ eer 36 37 12M1760 DESCRI
419. itted the correct way up with the turned spring end in the longer recess Press the spring eyes into alignment whilst the pad retaining pin is inserted through the caliper 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 caliper Anti rattle spring Inboard pad Turned spring end in longer recess Outboard pad Pad retaining pin Refit the roadwheels and press the brake pedal several times to set the brake pad position Before switch ing on the ignition check the fluid level in the reservoir and top up if necessary 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 JH 5 PARKING BRAKE MECHANISM Operation of the handbrake 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 calipers At each caliper the cable connects to a lever which operates the hydraulic piston by mechanical means Movement of the caliper 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
420. ivots engine rear stabiliser and exhaust muffler Onto each top side of the subframe is bonded and rivetted a box section extrunded alloy longeron which extends rearwards to provide rear body support Enhanced stiffness of the chassis rear section and additional occupant protection is provided by a tubular steel roll over bar which bolts to the top of the siderails alongside the fuel tank bay with bracing struts running from each top corner of the bar to the rear ends of the siderails At the front of the passenger compartment four transverse extrusion beams are used to provide mount ings 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 A extruded floor section is used to reinforce this area with the space between the front ends of the siderails housing the heater unit and battery An extruded scuttle beam links the tops of the siderails mounts the steering column and is reinforced by a panel joining this beam with the steering rack crossmember the panel also serving to mount the pedal box Each end of the scuttle beam carries a vertical extrusion to mount 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
421. j X Parts Required CO Carbon Fibre Airbox A111E0020S 1 WT including Ducting amp Clips A111E0022S 1 Adaptor Adaptor A111E0023K 1 Remove the new air cleaner element from the backplate by releasing the four socket head screws Oil the filter ele ment with the ITG aerosol to give an even coverage then gently massage the oil into the depth of the foam Feed the air cleaner element into the new airbox fit the airbox onto the backplate and secure the airbox and cleaner with the four screws Remove the existing profile adaptor from the LH air intake and fit the new adap tor and ducting LH air intake Ducting Airbox Foam air cleaner element Airbox fixing Page 4 Lotus Service Notes Section 7 Fit new engine breather hoses Parts Required Breather Hose Kit A111E0035J 1 Assemble the cam cover breather pipe assembly as shown and connect to the two cam cover spigots and airbox grommet Grommet A082L6181F y Adaptor A111E6153S Hose A111E0029S T piece A111E6152S Hose A111E0032S Clip A111E6154S Clip A111E6155S Hose A111E6151S 8 Ifthe oil cooler kit is to be fitted replace the oil filter housing with the new item and fit the 90 adaptor for the oil pressure switch 9 Refit the clutch and transmission sub section QF 4 to the engine and fit the complete power unit back into the car sub section EE 3 Note that the luggage bay bulkhead is not re fitted 10 Fit the ne
422. joint plinth to the hub carrier noting and retaining the camber adjustment shim pack 5 Release the bolt securing the outer end of the toe link to the hub carrier noting the conical spacer 1999 01 Caliper plate fixing screws 10 11 12 13 Section DE Extended boss Caliper mounting plate Use a puller tool if necessary to extract the outboard driveshaft from the hub Remove the four screws retaining the lower ball joint plinth to the hub carrier and withdraw the hub carrier assembly to a bench Use a hydraulic press to remove the hub from the bearing and if necessary use a puller to withdraw the bearing inner race from the hub spigot Remove both circlips from the hub carrier and press out the bearing Before fitting the new bearing clean any corrosion from the bearing bore outside of the circlip grooves and fit one circlip into position Heat the hub carrier in an oven to 90 C for at least 20 minutes before pressing the bearing assembly into the carrier to abut the fitted circlip Retain by fitting the second circlip Before fitting the hub check whether the caliper mounting plate needs to be removed or replaced as access to the lower fixing is inhibited with the hub in place When fitting the plate to the hub carrier ensure that the correct hand of plate is fitted with the extended boss positioned at the outboard top The fixing method of the caliper mounting plate to the hub carrier was c
423. ke alloy wheels made by Rimstock Both types are mounted on standard Elise hubs using longer 42mm protrusion instead of 36mm studs but standard wheelnuts The magnesium wheels common in size and inset to the race wheel set 6J x 15 front 8J x 16 rear inset 10mm front and rear with the alloy wheels differing only the rear rim width 7 5J and rear inset 4mm All wheels should be carefully and regularly cleaned especially if used on salted roads Before fitting magnesium wheels a coating of Duralac anti corrosive compound A111C6017S should be applied to the hub mating face to prevent electrolytic corrosion Wheel nut torque for all wheels is unchanged from standard Elise at 80 85 Nm but it is most important that following the first fitment of a NEW MAGNE SIUM wheel the wheel nuts are retorqued after 25 miles driving to allow for material settlement The Yokohama A038 R tyres fitted to the Elise 340R have been jointly developed by Lotus and Yokohama specifically for Elise models and whilst the specification is optimised for track use the tyre is road legal in the U K and some European markets The tyre offers a high level of grip in both dry and wet track conditions combined with good braking performance The water clearing ability of the tyre is limited in standing water such that appropriate allowances should be made in these conditions For competition use the eligibility of the tyre should first be checked with the appropria
424. ket oe Horseshoe compensator Parking brake cable adjuster The parking brake lever is sandwiched into a mounting bracket by two flat head bolts securing the ratchet plate The mounting bracket in conjunction with the gearchange lever bracket is not drive handed but is offset via alternative fixing holes in the chassis towards the passenger side The ratchet 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 secured to both the lever assembly and the compensator horseshoe by clevis pins with retaining R pins Parking brake lever Front cable Ratchet plate Micro switch Mounting bracket Gear lever mounting bracket Page 8 Lotus Service Notes Section JH JH 6 BRAKE DISCS All four wheel brakes utilise a common brake disc which is sandwiched between each wheel and its hub being centralised by the hub spigot and transmitting torque via the clamping force of the road wheel studs No separate disc fixings are used The discs are made from an aluminium metal matrix incorporating silicon carbide and must only be used in conjunction with the special brake pad material specified deposit from the brake pads which builds up on the swept area of the discs with use and is evidenced by a dull grey band contributes to the friction characteristic and braking efficienc
425. ket on the transmission and is connected to the clutch operating lever by a fixed length pushrod and clevis pin A sleeve nut is used to connect the flexible hydraulic pipe and a bleed nipple is provided by which to bleed air from the hydraulic system Bleed nipple Clutch slave cylinder Mounting bracket Operating lever Pushrod Flexible pipe 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 Remove the R pin and clevis pin connecting the pushrod to the clutch operating lever Disconnect and immediately plug and cap the hydraulic hose connection LE ne 1998 02 JI Lotus Service Notes Section QF Remove the two bolts securing the cylinder to the mounting bracket and withdraw the cylinder To refit reverse the removal procedure tightening the slave cylinder mounting bolts to 25 Nm Clean and refit the specially coated clevis pin and R pin to connect the pushrod to the release lever and check that the pushrod is correctly centralised in the siave cylinder piston Tighten the hydraulic pipe connection to 20 24 Nm and bleed the hydraulic system of air in the usual way Tighten the bleed nipple to 7 Nm To overhaul the slave cylinder Clamp the cylinder in a soft jawed vice and withdraw the pushrod and rubber dust boot from the
426. key tell tale will light steady 4 Press either one of the transmitter key buttons the transmitter key tell tale will blink and the alarm tell tale in the instrument pod will go out for one second 5 Repeat 3 and 4 for all other transmitter keys to be used up to a maximum of four When all keys have been programmed switch off the ignition alarm tell tale will go out Note that this programming procedure erases all existing transmitter codes so that all keys to be used must be reprogrammed at the same time Checking the Alarm System To ensure that optimum vehicle protection is maintained the alarm system function should be checked periodically 1 Arm the alarm and wait for 40 seconds 2 Open either door The siren should sound and the hazard lamps flash for 30 seconds To turn off the siren before the 30 seconds have elapsed press the large button on the transmitter key this will not disarm the alarm 3 Repeat step 2 testing the opposite door the engine lid and the front bonnet Manually operate the sensor switches to test the engine lid and front bonnet 4 engine lid or front bonnet are left open the alarm will stop after approximately 30 seconds and then repeat after a short delay and continue in this sequence for ten cycles 5 To test the intrusion sensing arm the system and within the 30 sec arming period check that substantial body movement within the cockpit triggers the alarm as indicated by the sounding of th
427. khead Fettle and or modify the engine cover lid as necessary to provide sufficient clearance to new intake plenum Fill the engine with a good quality mineral not synthetic oil meeting the viscosity requirements of the standard engine see Owner s Handbook or Service Notes Section OG and change the oil and filter after the running in period of 1 000 miles Part or fully synthetic be used to advantage after running in with the same viscosity requirement Note that for the hydraulic tappets to prime the engine may require cranking for an extended period For normal road use the standard maintenance schedule may be used with oil and filter changes at 9 000 mile intervals For cars used on circuit track days it is recommended to reduce the change interval to 3 000 miles and for full race use change every two meetings aa 1999 01 8 Lotus Service Notes Section XA 15 YOKOHAMA A038 R COMPETITIO R The Yokohama A038 R tyre has been jointly developed by Lotus and Yokohama specifically for the Lotus Elise and whilst the specification is optimised for track use the tyre is road legal in the U K and Europe The tyre offers a high level of grip in both dry and wet track conditions combined with good braking performance The water clearing ability of the tyre is limited in standing water such that appropriate allowances should be made in these conditions For competition use the eligibility of the tyre should first
428. king strip is fitted to the top part of the windscreen pillar degrease the appropriate area on the pillar and apply PP Primer 3842 A082U6199V to both the pillar and packing strip Lay double sided tape onto the pillar and fit the packing strip tapered end downmost into position snugly against the sides of the recess To fit the weatherstrip Shape the front end of the seal to fit in the recess in the windscreen Weatherstrip cut to header rail fit into header moulding Degrease the landing area and apply PP Primer to the aperture and seal bonding surface includ ing the screen pillar foam pack Foam packing strip ing strip Apply double sided tape around the aperture Fit the weatherstrip onto the tape positioning snugly against the sides of the recess Leave suffi cient length at the rear end of the seal to allow it to be capped by the roll bar fairing Page 18 amp Lotus Service Notes Section BN Insert the buffer into the rear end of the weatherstrip by threading a stiff wire down the centre of the seal via an entry hole through the rear face of the seal approximately 25 mm below the latch striker pin Attach the buffer to the wire and draw the buffer through the seal until centralised about the latch striker pin Remove the wire and seal the hole in the weatherstrip Top end of door weatherstrip Cut off Buffer loop after centralised positioning about striker pin Door Weir A 377 mm length of
429. king tool 1 1570 9 NN OO T96 M124937 8 Fit flywheel locking tool 18G 1674 tighten bolt CAUTION Ensure tooth on tool 18G 1674 engages with teeth on flywheel not the reluctor ring M124954 5 Check that timing mark on crankshaft pulley is aligned with mark on timing belt lower cover OVERHAUL 5 ENGINE All engines 461 9 Remove crankshaft pulley bolt and washer remove crankshaft pulley 10 Remove 3 bolts securing timing belt lower cover 11 Remove timing belt lower cover together with seals ke 124925 NOTE Non VVC camshaft timing gears ZN and tensioner spring illustrated e 12 Slacken tensioner pulley Allen Screw 13 Slacken tensioner backplate screw 14 Push tensioner pulley Sih to fully OFF 4 position 3 engines Tensioner spring G and pillar bolt are only fitted for tensioning replac ment timing belts 15 Tighten backplate screw to 10 Nm 16 Ease timing belt from gears using the fingers 2 aug 17 Discard timing belt CAUTION Timing belt must always be replaced during engine overhaul Do not rotate crankshaft with timing belt removed and cylinder head fitted i HER 6 OVERHAUL ENGINE desse Camshaft timing belt manual tensioner refit CAUTION VVC engines When replacement timing belt is to be fitted it will be necessary to fit the tensioner spring and p
430. l fettling but with care no painting should be required 3 Refitthe driver s seat and seat belt harness Note that with this bar fitted a passenger seat MUST NOT be fitted 135 mm 100 mm EM UNE a D lt gt bd Page 50 Lotus Service Notes Section XA Profile of backstay clearance slot in engine lid actual size RHD shown LHD mirror image 2000 02 EE 3408 SUPPLEMENT Sub Section Page Introduction 340R 2 Technical Data 340R TD 2 Chassis 340R A 3 Body 340R B 4 Front Suspension 340R C 8 Rear Suspension 340R D 9 Engine 340R E 9 Transmission 340R F 16 Wheels amp Tyres 340R G 17 Steering 340R H 18 Braking 340R J 18 Cooling 340R K 18 Fue System 340R L 18 Electrical 340R M 19 Maintenance amp Lubrication 340 46 Heating 340R P 50 Clutch 340R Q 50 2000 02 340R INT CTION The Elise 340R made its debut at the 1998 Birmingham Motor Show as a radical lightweight sportscar concept focused on pure driving pleasure Minimal changes were required to meet European homologation regulations and the car commenced production in January 2000 The car is based on the standard Elise chassis but uses completely different bodywork and interior and a road going version of the Rover VHPD powertrain The car embodies the original philosophy of the Elise with performance achieved through light wei
431. l system is unchanged from standard Elise Unleaded fuel with a minimum octane rating of 95 RON should be used 2000 03 5 Serie Neies ELECTRICA VEHICLE SECURITY The Exige uses the same vehicle Meta security system as is used on 340R being either an M36 T2 electronic immobiliser meeting Thatcham category 2 requirements or as an optional upgrade a full M99 T2 alarm system incorporating M23 cockpit intrusion sensing and a self powered siren which meets Thatcham 1 The Lucas 5AS security module used on the standard Elise is not fitted The Meta system operates as follows Keys amp Vehicle Security Alarm A single key operates the doors and combined ignition switch steering lock with a second smaller key type for the fuel filler cap The head of each ignition key incorporates an electronic transmitter for operation of the engine immobiliser and security alarm system Duplicates of both keys are supplied with the new vehicle The key numbers are stamped on the keys themselves and should be recorded by the owner and kept with the vehicle documents to enable the dealer to have replacements made if necessary Standard immobiliser In order to provide a measure of automatic vehicle security independent of any driver initiative the Meta M36 T2 immobiliser will passively immobilise the engine s cranking and running circuits about 20 seconds after the ignition has been turned off The immobilised state w
432. l than the Sport 190 version is supplied with air via large diameter trunking drawing ambient air from the intake duct in the left hand body ahead of the rear wheelarch Incorporated in the intake trunking at the entrance to the airbox is a butterfly valve which is controlled by the engine management system and is designed to suppress resonant intake noise under certain engine operating conditions The valve is sprung open and is closed by a vacuum actuator supplied via a pair of solenoid valves mounted at the LH side of the engine bay The solenoid valves are controlled by the engine management ECM which is programmed to close the butterfly valve when accelerating with wide throttle through the lower gears at about 30 40mph The flap capsule is connected to a vacuum charging solenoid valve which either ventilates the the cap sule or connects it to vacuum locking solenoid valve The locking valve either seals the charging valve or connects with the manifold vacuum supply via a reservoir mounted on the roll over bar back stay Vacuum reservoir MAP sensor E Baro sensor SO Resonator valve actuator Locking solenoid valve Charging Resonator valve solenoid valve housing AE Vacuum supply hose Inlet tracts Vacuum reservoir MAP sensor Fuel pressure regulator Locking solenoid valve Resonator valve actuator Charging solenoid valve 727 2000 03 tt E Lotus Service Notes Exige The sequence of operation is as follo
433. lamp the outer cable to allow full flap movement to be obtained RHD viewed from beneath Distribution flap lever Distribution control cable E Footwell outlet vent pss LHD cars The cable connects to the top end of the flap spindle with access improved by the removal of the wiper mechanism With the selector lever at defrost the flap spindle should be turned fully clockwise and the cable hooked into the hole nearest the spindle Position the lever on the spindle and clamp the outer cable to allow full flap movement to be obtained LHD within front services compartment Spring clip Distribution control cable 546 Distribution flap lever Connection to scu f demist duct 2 P d TAN Page 6 E Lotus Service Notes Section PF Equal arcs Control cable Ideal adjustment of control cable to attain equal arcs of flap lever travel Flap lever HEATER MATRIX amp BLOWER FAN UNIT The heater matrix is sandwiched between two plastic mouldings and is clamped to the blower fan unit by a rubber strap The complete assembly is secured via thread inserts in the chassis front well by two screws through a bracket on the front of the fan unit and a single screw through the fan casing at the rear accessible after removing the outlet ducting An additional screw secures the heater matrix inlet moulding via a bracket on the top front edge Fan housing bracket to chassis front Fan housing
434. lbow Exhaust valve guide Exhaust valve Valve seat insert exhaust Valve seat insert inlet Inlet valve Inlet valve guide Cylinder head gasket Valve stem oil seal Valve spring Valve spring cap Collets Hydraulic tappet Bolt cylinder head Camshaft cover Bolt camshaft cover O ring camshaft sensor Camshaft sensor Bolt camshaft sensor DESCRIPTION AND OPERATION 111 ENGINE TIMING BELT COMPONENTS K8 ENGINES M124934 1 Upper front cover timing belt 2 Seal upper cover 3 Screw M6 x 16 upper cover 4 Bolt M6 x 40 upper cover 5 Bolt M6 x 20 upper cover 6 Flange shoulder screw upper cover 7 Lower cover timing belt 8 Seal lower cover to mounting 9 Seal lower cover to cylinder block 10 Screw lower cover 11 Screw M6 x 16 lower cover 12 Crankshaft pulley 13 Special washer pulley bolt 14 Crankshaft pulley bolt 15 Tensioner pulley and backplate 16 Allen screw tensioner to cylinder head 17 Flange head screw tensioner backplate 18 Tensioner spring 19 Sleeve spring 20 Pillar bolt 21 Camshaft timing belt 22 Crankshaft timing gear 23 Camshaft timing gear 24 Camshaft gear bolt 25 Plain washer 26 Upper rear cover timing belt 27 Screw rear cover to coolant pump 28 Screw rear cover 12 DESCRIPTION AND OPERATION ENGINE 9 TIMING BELT COMPONENTS 16 NON VVC
435. le opening For example when a fully closed throttle and appropriate engine speed is signalled the ECM activates the idle air control valve to regulate idle speed a rapid or sudden opening of the throttle will initiate fuel enrichment for acceleration and a closed throttle overrun condition will prompt fuel cut off Clamping plate Throttle Position TP sensor The ECM provides the sensor with a 5 volt supply and monitors the returning signal which is proportional to throttle opening on an earth line Acceleration enrichment When the throttle pedal is depressed the ECM receives a rising voltage from the TP sensor and detects a rise in manifold pressure from the MAP sensor The ECM provides additional fuel by increasing the normal injector pulse width and also provides a small munmer of extra pulses on rapid throttle openings Over run fuel cut off The ECM implements over run fuel cut off when the engine speed is above 2000 rpm with engine at normal operating temperature and the throttle position sensor in the closed position i e the vehicle is coasting with the throttle released The ECM indexes the idle air control valve open slightly to increase the air flow through the engine to maintain a constant manifold depression and keep emissions low Fuel is progressively reinstated as the throttle position sensor is opened When using the Lotus Check scanner tool Throttle Bits shows the raw signal received by the ECM from the TP sens
436. lean side to the dirty side This will remove dirt and not drive it into the filter 5 Always let excess water drain from the filter Let the filter dry naturally Never use compressed air open flame or hot air dryers 6 After cleaning the filter Pipercross Dirt Retention Additive DRA must be re applied Pipercross DRA is a very efficient high tack polymer Never use motor oil diesel fuel ATF or WD40 7 Re install the filters and intake ducting Note that the intake trunking is marked with an arrow indicating the direction of airflow for optimum perform ance 2000 03 Page 15 LOrE Exhaust System The Exige and 340R use a special exhaust manifold fabricated from 45mm steel tube leading via a short flexible section to the standard catalytic converter and then into the transverse muffler The Exige muffler is based on that of the 340R the body of which is more voluminous than the standard Elise muffler but in this application no external wrap is used and the bigger bore tailpipes are 50mm diameter with correspondingly larger trims Starting Procedure The fuel injection and engine management system controls fuel delivery and engine settings under all normal operating conditions i If necessary mobilise the engine by pressing the ignition key head transmitter button see Vehicle Secu rity Alarm ii Insert the ignition key into the switch steering lock and turn to position Il to switch on the ignition note that
437. learance Valve stem fitted height new service limit VALVE GUIDES Inside diameter Fitted height VALVE SEATS Seat face angle VALVE SPRINGS Std Free length Fitted length Load at fitted length Load at full lift VVC Free length Fitted length Load at fitted length Load at fuli lift CRANKSHAFT Crankshaft endfloat new service limit Thrust washer thickness Main journal diameter Maximum out of round Big end journal diameter Maximum out of round Big end clearance PISTON RINGS New ring to groove clearance top compression second compression oil control New ring gap 20mm from bore top top compression second compression oil control PISTON Piston diameter 8mm from bottom 90 to grade A grade B Clearance in bore 20mm from bottom of bore CYLI R BLOCK Cylinder liner bore 65mm from top red grade blue grade B 0 033 0 063 mm 0 070 mm 0 038 0 078 mm 0 110 mm Hydraulically controlled 38 93 39 84 mm 40 10 mm 6 000 6 025 mm 6 0 mm 459 50 0 mm 37 0 mm 250 12N 450 18N 47 6 mm 37 0 mm 210 13 440 22 0 10 0 25 0 34 2 61 2 65 47 979 48 007 mm for grading see Section EE 0 010 mm 47 986 48 007 mm for grading see Section EE 0 010 0 021 0 049 mm 0 040 0 072 mm 0 030 0 062 mm 0 010 0 180 mm 0 20 0 35 mm 0 28 0 48 mm 0 15 0 40 mm 79 975 79 990 mm 79 991 80 005 mm
438. let 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 In order to prevent the possibility of ice formation at the evaporator a thermostatic switch is housed inside the evaporator casing with a temperature sensing capillary line inserted into the outlet side of the finning The switch is used to cycle the compressor on and off as necessary to maintain the minimum output air tempera ture without danger of icing 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 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 the cylinder head outlet pipe via an alloy pipe running along the outside of the RH chassis side rail Coolant is returned via a similar pipe along the LH chassis rail to the engine side of the thermostat housing Air temperature is controlled by an air blend flap within the heater housing which directs a varying propor tion of the airflow through or around
439. lignment 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 rear bolts requires that the door glass first be released 1 Remove the trim panel around the interior release handle Remove the two screws in the front edge of the finisher and unhook the finisher from the handle and door shell 2 Release the three screws securing the interior release handle and unclip the control rod from the mecha nism 3 Remove the door trim panel Unclip the cap from the window winder handle release the retaining screw and withdraw the handle Release the seven fixing screws and remove the door trim panel 4 Removethe two M6 and the single M8 screws securing the door beam flange to the front of the door shell 5 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 ailow access to the two 8 bolts fixing the rear end of the door 1998 01 SE E Lotus Service Notes Section BN beam to the extension bracket Remove the bolts noting any spacer
440. linth Road Test Performance Engine performance 2 Brake performance Cl tch operation pr mter rr Pec Ge PER Gearbox operation Steering performance Wheel balance Driveline amp suspension noise vibration o aie eem irte ep de Saure e eR General comments aeree ret aepo el e eee pa eh ee d Ferca ce dee ER Dee Ene reda a nate Additional work requited ER Eten ee tad dee e De ERE e dne Notes Dealer stamp The PDI is subject to the following conditions a Itis 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 are the responsibility of the supplying dealer c Failure to return a signed copy of this inspec Dealer signature tion to Lotus Cars Ltd by the dealer may result in warranty claims on the particular car being rejected SE 1998 03 eS Lotus Service Notes Section PF HEATING amp VENTILATION SECTION PF M111 ELISE Sub Section Page General Description PF 1 2 Control Cables PF 2 4 Heater Matrix amp Blower Fan Unit PF 3 7 Page 1 E
441. lt 205 Nm Cylinder head bolts All bolts 20 Nm Mark position of radial marks Turn all bolts 180 bolts another 180 align marks Dipstick tube bolts 10 Nm 80 Nm Fuel pump blanking plate nuts K8 25 Nm ht lead brackets not plug top coil ignition 10 Nm ht lead cover screwS 5 Nm Hydraulic control unit bolts K16 VVC engines 25 Nm Hydraulic control unit piston to rack screw 9Nm Hydraulic control unit oil temperature transmitter 15 Nm Hydraulic control unit spool valve nut K16 VVC engines 26 Nm Hydraulic control unit spool valve sleeve bolt K16 VVC engines 12 Nm Ignition coils to cylinder head plug top coil ignition only 8 Nm K16 VVC housing bolts 10 Nm Multiplug bracket to camshaft carrier bolts if fitted 10 Nm Oil filter 12 Nm pump bolts 10 Nm Oil railinutS 9Nm Oil suction pipe to bearing ladder bolts 12 Nm Oil temperature sensor to oil filter 17 Nm Pressed steel sump bolts M6 M8 10 Nm Tighten in sequence New
442. lues e g 8096 for fuelling being too rich Note misfire conditions will be shown as high values as feedback will be fooled into compensating for a system running too lean The sensor is mounted on the inner side of the exhaust manifold just upstream of the downpipe flange To remove the sensor unplug and free the electrical connector and use a 22 mm crows foot spanner to release the sensor from the manifold Fit a new sealing washer to the sensor before tightening to 55 Nm and mating the electrical connector plug 2000 01 S Lotus Service Notes Section EMN FT The camshaft position sensor has two functions 1 to provide an engine position reference for the sequen tial injection ii to measure the actual inlet cam period as controlled by the VVC mechanism The inductive type sensor is mounted on the right hand side of the cylinder head and projects into the cam housing to be in close proximity to a toothed reluctor on the inlet camshaft of no 2 cylinder By interpreting the signals received the ECM is able to distinguish firing TDC from exhaust TDC and initiate the injection sequence on engine start If however the sensor should fail before engine start the engine will start and continue to run in grouped fuelling mode injectors activated in pairs with a reduced rev limit of approx 5 600 rpm applied to protect the engine from potential damage If sensor failure occurs whilst the engine is running the en
443. lycol anti freeze provides protection against these dangers as well as raising the boiling point of the coolant The car is factory filled for all markets with a 50 concentration of anti freeze which provides freezing protection down to approximately 35 C 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 Density Concentration 20 C 60 C 25 1 039 1 020 33 1 057 1 034 50 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 24 months 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
444. m ovality 0 3 mm Cylinder block Cylinder liner bore K8 and K16 1 1 and 1 4 RED grade A gio 74 970 to 74 985 mm BLUE grade 74 986 to 75 000 mm K16 1 6 and 1 8 RED grade 80 000 to 80 015 mm BLUE grade 80 016 to 80 030 mm A gS E eT 4 DATA TORQUE amp TOOLS TORQUE WRENCH SETTINGS Air cleaner support bracket bolts 10Nm Alloy sump bolts ME XIS teet i e A e EUR 25 Nm 60 teur tet edd 30 Nm Bearing ladder to block bolts 30 Nm Big end bolts 20 Nm lt Blanking plate to camshaft carrier bolts Not plug top coil ignition system 25Nm Plug top coil ignition system Inlet camshaft 6 Nm Exhaust camshaft 25 Nm Camshaft carrier bolts 10 Nm Camshaft cover to carrier bolts 10 Nm Camshaft gear bolts Ss Mote 35 MAO EE 65 Nm Camshaft sensor bolts 16 engines 5 Nm Coolant pump bolts 10 Nm Coolant rail to cylinder block bolts 25 Nm Crankshaft pulley bo
445. mate to the top and bottom joint flanges of the bulkhead and also to the sill flange if one sill is already fitted Fit the bulkhead into position with the vertical flange on the bottom of the panel against the rear face of the chassis fuel tank bay Fit the capping rail to the top flange of the bulkhead 4 Fit the sill panel s as detailed sub section BM 9 and fit the button head screw to secure the top of each sill B post to the capping rail Clamp the sill s and bulkead capping rail into position until the adhesive has cured There should be a gap of approx 3 mm between the top ends of the capping rail and the roll over bar Apply additional Betaseal to fill the gap between capping rail and the roll over bar stays and smooth with a spatula for a neat finish Page 18 E Lotus Service Notes Section BN BODY FITTINGS SECTION BN M111 ELISE Sub Section Page Soft Top Roof BN 1 2 Front Bonnet BN 2 4 Engine Cover Lid BN 3 5 Front Clamshell BN 4 7 Rear Clamshell BN 5 8 Door Mirrors BN 6 10 Door Beam amp Hinge BN 7 12 Door Shell Assembly BN 8 13 Door Glass Guide Channels amp Winder Mechanism BN 9 14 Door Seals BN 10 17 Door Latch Mechanism BN 11 20 Instrument Binnacle amp Dash Panel BN 12 22 Windscreen BN 13 25 Roof Header Retaining Strip BN 14 28 Decal Positioning BN 15 29 Rear Boot Bulkhead BN 16 30 Page 1 627 Lotus Service Notes Section Lotus Service Notes Section 1_ SOFT TOP ROOF
446. mble cylinder liner retainer clamps 18G 1736 to cylinder head bolts Position retainer clamps on cylinder liners ensuring clamps do not protrude over liner bores Screw cylinder head bolts into rail and tighten sufficiently to retain clamps CAUTION Ensure that bolts used are those originally fitted in that location gt M124930 1 Remove and discard camshaft timing belt CAUTION Do not rotate crankshaft whilst timing is removed and cylinder head is fitted pistons will contact the valves 2 Engines fitted with manual timing belt tensioner Disconnect tensioner spring remove bolt screw tensioner and spring OVERHAUL 25 ENGINE 124931 9 26 Release 2 screws and remove spark plug cover Disconnect 4 plug tubes from spark plugs Remove any debris from spark plug recesses remove and discard 4 spark plugs Lift clip plate and grommet and position plug leads aside Remove 2 bolts and air cleaner support bracket Progressively slacken then remove bolts and on early engines 2 pillar bolts securing camshaft cover NOTE On later engines pillar bolts have been replaced by cast in supports which are an integral part of the camshaft cover Remove camshaft cover assembly remove and discard gasket Check and record crankshaft end float OVERHAUL Release 2 screws and remove distributor cap Remove and discard screw securing rotor arm Re
447. mend the use of any hide food and prohibit the use of petrol or detergents furniture creams and polishes Senotex Coated Tr m Some areas of the interior including the scuttle and rear bulkhead are finished with a grey textured Senotex coating Stains may be removed using a proprietary upholstery cleaner and a soft bristle brush Finish by wiping over with a dry soft cloth Seat Belts Cleaning The seat belts should be sponged with warm water and allowed to air dry naturally Do not use chemical cleaners and never attempt to bleach or dye the webbing BM 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 Services Compartment Lid Note that the engine cover lid is aluminium 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 the front and rear clamshells and doors are contained in section BN Bonded on Panels Windscreen Frame LH amp RH Sill Panels Front Crash Structure Rear Bulkhead amp Capping Rail These panels are bonded to the chassis or to other panels using a flexible polyurethane adhesive which must be cut before the panel may
448. mfer on the inside diameter of the stop washer should face rearwards i e towards open end of cylinder Master cylinder body Piston washer Secondary seal Primary seal Pushrod Piston Stop washer Circlip Dust boot Vc ll EN in e Spring Spring retainer Piston washer Secondary seal Pushrod EENHEETEN EE EE EEN 1000 1019 5 Lotus Service Notes Section QF On reassembly scrupulous cleanliness is essential Clean hands thoroughly beforehand Lubricate all seals the cylinder bore and all internal components with clean brake fluid Fit the secondary seal into its groove on the piston with the lip towards the front Fit the piston washer primary seal and spring retainer onto the front end of the piston with the lip of the seal facing forwards Insert the spring and piston assembly into the cylinder taking care no to bend back the seal lips Fit the stop washer and retain by fitting the circlip into the groove in the rear end of the cylinder bore Check that the circlip is seated correctly in the groove Pack the inside of the dust boot with rubber grease and seat the lip of the boot in the groove on the outside of the cylinder body Use a suitable rod to operate the piston by hand several times to check for free movement of the internal parts Refit the cylinder as detailed above Slave Cylinder The slave cylinder is secured by two bolts to a mounting brac
449. milar arrange ment is used at the output end of the cable which connects to the heater or distribution flap spindle via a lever with a boss and grub screw The lever is equipped with three holes for use in different applications Control lever Dash centre assembly Graphic extrusion Plastic panel insert panel Fan speed switch 6 The heat contro cable runs forward through the scuttle blanking panel and down to the heater matrix housing in the chassis front well Hook the inner cable into the outermost hole in the temperature flap lever and with the temperature selector lever positioned at bot ensure that the flap is in the fully hot position counterclockwise on RHD clockwise on LHD before tightening the operating lever grub screw onto the flap spindle and clamping the outer cable with the spring steel clip Spring steel clips Temperature flap fever Cable abutment on matrix housing Control lever baseplate Page 5 Lotus Service Notes Section PF 7 distribution control cable runs from the upper selector lever to the bottom of the flap spindle on RHD cars and to the top of the flap spindle on LHD cars RHD cars Access to the distribution flap lever is available from within the passenger footwell With the selector lever at defrost the flap spindle should be turned fully clockwise when viewed from beneath and the cable hooked into the middle hole in the lever Position the lever on the spindle and c
450. mise any fire hazard The inertia switch is mounted at the left hand front corner of the rear luggage compartment be hind the engine and is reset by pressing the rubber diaphragm button on the top of the unit Page 14 Lotus Service Notes Section amp MN 4 COMPONENT LOCATION amp FUSE RATINGS Main Fusebox A The main fusebox is located in the front services compartment on the passenger side and is protected by a clear plastic cover Twelve Littel type fuses are fitted alongside four relay modules The fuses are numbered and coloured according to their amperage rating and may be pulled out from their slots using the fuse extractor too stowed within the fusebox Spare fuses are also housed within the fusebox Note that the fusebox position is reversed on left hand drive cars Fuses Slot Rating Circuit RHD D B A 1 3A Rear fog lamp shown 2 2 Alarm ignition 12 1 3 15A Interior fans 4 15A Wiper motor 5 Reverse lamp 6 7 5A Direction ind 5A Ignition services 8 7 5A Stop lamps amp batt serv 9 10A Hazard lamps 10 7 5A Horn 11 10 Alarm pwr amp int lamp 12 25 Cooling fan Relays Horn B Cooling fan C Dip beam D Main beam Eusebox B for cars Feb 97 on see also MN 1 Removal of the wiper motor cover two screws RHD shown allows access to a second fusebox containing 4 Littel fuses and also to a pair of Maxi fuses Note that the order of fuses on LHD c
451. mon at 100mm front and 110mm rear with sport kit steering rack positioning plates factory fitted The standard setting for the front anti roll bar is the central of 5 available holes Geometry Ride height for geometry check front 100 mm below front end of chassis siderail rear 110 mm below rear end of chassis siderail Steering axis inclination 12 nominal Castor 3 85 02 max side side 0 2 Road use Yokohama A038 R or Pirelli P Zero tyres Camber 0 5 0 1 0 2 max side side 0 2 Alignment 0 2 mm toe out overall 0 2 mm 0 Dry track use Yokohama A038 R tyres Camber 1 8 0 1 0 2 max side side 0 2 Alignment 0 5 mm toe out overall 0 2 0 Page 8 Or 40R D P The 340R is fitted with the Elise Sport suspension package which includes adjustable spring platform Koni dampers with the shorter and stiffer springs Standard Elise forged steel hub carriers and wishbones are used with the wishbones integral stud type toe links and upper ball joint plinths powder coated in silver Two variations of suspension geometry are specified one for road use with Yokohama or Pirelli tyres and one optimised for track use with increased negative camber and toe settings Ride height for both applications is common at 100mm front and 110mm rear with sport kit steering rack positioning plates factory fitted For optimum rear bump steer set up information refer to sub section XA 8 Geometry Ride
452. move rotor arm Remove anti flash shield M 124973 NOTE Later engines are fitted with modified camshafts which incorporate a reluctor ring and the procedure for removing cylinder head bolts differs from early engines Commencing engine numbers for the modified camshafts are listed tn information 8RM 0740 14 Using sequence shown progressively slacken cylinder head bolts Early engines bolts 1 to 8 remove bolts 1 to 8 and store in fitted order Later engines fitted with modified camshafts bolts 1 to 6 remove bolts 1 to 6 and store in fitted order NOTE It will be necessary to carry out the following operations in order to remove the remaining bolts 18G 1570 12 182 12 0576 15 Remove locking tool 18G 1570 from camshaft gears 16 Using tool 12 182 turn both camshafts clockwise to gain access to bolts Early engines bolts 9 and 10 Later engines fitted with modified camshatfts bolts 7 and 8 Progressively slacken then remove the remaining bolts and store in fitted order CAUTION Removal of cylinder head bolts results in a tightening up of crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G 1736 are fitted 17 Suitably identify each camshaft gear to its respective camshaft and using tool 12 182 to hold camshaft gear against rotation remove bolt and plain washer from each camshaft gear
453. move the six bolts securing the clutch housing to the engine 2 bolts to the sump 1 bolt each side through the block lower wings 2 bolts securing the top of the clutch housing to the engine Pushing the engine to the right and downwards at the flywheel end withdraw the transmission from the engine Inspection of components 13 14 Before removing the clutch cover from the flywheel place a flat plate over the ends of the diaphragm spring fingers and use a feeler gauge to measure the any gaps between individual fingers and the plate If any clearance is greater than 1mm the clutch cover assembly should be replaced Progressively loosen and then remove the six fixings securing the clutch cover to the flywheel Remove the cover and friction plate Flywheel Friction plate Clutch cover Release bearing Release fork Release lever amp shaft Spring wire clip Page 10 1998 07 Lotus Service Notes Section QF 15 Examine the friction plate for oil contamination broken cush drive springs cracking of the Total thickness spring apertures or any other damage minimum 5 6 mm Measure the overall thickness across the friction material New thickness 6 9 7 4 Service limit 5 6 mm Measure the depth of the rivet heads below the friction material surface New rivet depth 1 0 mm Service limit 0 2 mm Measure axial run out of the friction plate zx Bg Rivet depth surface m
454. mpressor Fitment 1 Fit the compressor to the engine with the drive belt positioned and secure with the three M10 bolts Tighten to 43 47 Nm Tension the drive belt as detailed above 2 Using new O rings lubricated with an approved refrigerant oil fit the two refrigerant pipes to the compres sor and tighten the fixing screws to 23 27 Nm Secure the pipe clamp adjacent to the service ports 3 Connect the compressor clutch cable 4 Recharge the system with R134a refrigerant 10 CONDENSER The condenser is mounted beneath the engine cooling radiator in the front services compartment To replace the condenser the radiator mounting panel must be removed complete with radiator condenser and cooling fans 1 Remove the front clamshell see section BP 2 Release the fixings securing the water shield to the top rear edge of the radiator mounting panel and withdraw the shield 3 Drain the coolant and disconnect the feed and return hoses from the radiator 4 Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of the engine bay 5 Unplug the fan harness connector 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 2000 04 Radiator mounting panel Engine cooling radiator
455. mption and cooling fans running continuously 2000 7 01 Page 11 EG Lotus Service Notes Section EMN TEMPER The intake air temperature IAT sensor is fitted into the inlet manifold tract of no 4 cylinder and is a transducer with a negative temperature coefficient such that its electrical resistance reduces with increasing temperature Using this signal in conjunction with that from the MAP sensor the ECM is able to determine the air consumption of the engine and adjust the injector pulse width accordingly for correct fuelling Low air temperature results in denser air requiring more fuel High air temperatures are also used by the ECM to retard the ignition timing and avoid knock mu Ac ye e D replace the sensor unplug the electrical connector and unscrew the sensor from the manifold Before fitting a sensor clean the threads and mating face and screw into the manifold tightening to 7Nm Mate the harness plug 2000 01 E Lotus Service Notes Section EMN The ECM requires a coolant temperature input signal in order to increase fuel delivery and maintain driveability during the cold running and warm up phase The signal from this sensor is used for many different parameters within the engine management system to control and switch various components dependent on engine temperature The sensor is a thermistor a resistor which changes value
456. n Top up the master cylinder reservoir if necessary to bring the level to 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 JH 4 REAR BRAKE PAD REPLACEMENT Pad thickness may be checked after removing the road wheel without disturbing the caliper Alloy discs Iron discs Standard pad thickness excluding backplate 7 8 mm 6 5 mm Minimum pad thickness excluding backplate 2 5 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 different brake pads are used for aluminium and iron discs Aluminium discs These pads are identified by a stencilled number on the backplate commencing with BXD If desired self adhesive anti squeal overlays A111J0122F may be fitted to the pads after approx 0 75mm of wear has taken place but some loss of pedal feel will be incurred Iron discs These pads are factory fitted with anti squeal overlays and marked Brembo 07 7236 20 Pad retaining pin Tools Required Piston Retraction Tool T000T1242 O 0 GN 1 Remove the rear road wheels pt 2 At each rear corner using a suitable pin punch knock the pad retaining pin out of the caliper towards the outside taking precautions as necessary to restrain the anti rattle sp
457. n their original positions ear Clamshell The rear clamshell fixings differ from the standard Elise in using vertical alloy panels bonded to the shell either side of the luggage space and secured to the top surface of the rear longerons The front upper edge of the shell is secured to the rear edge of the roof panel and the bottom front edges of the clamshell wrap beneath the rear end of the sills The early type boot floor is used incorporating a rearward extension to pick up the clamshell behind the rear licence plate To remove 1 Remove both rear road wheels and wheelarch liners 2 Mark its position before releasing the tailgate panel from the hinge blade noting any shim plates Discon nect the release cable from the tailgate latch and release any cable fixings 3 Remove the trim panel from each side of the engine bay after releasing the fixings to the clamshell gutter and engine bay front surround 4 Remove the fuel filler cap and release the four screws securing the fuel filler neck to the clamshell Remove the washer ring and withdraw the neck from the clamshell aperture 5 Release the single screw each side securing the front of the clamshell gutter to the engine bay front surround 6 Release the three screws each side securing the clamshell support plates to the top of the longerons 7 Remove the rear number plate and release the single fixing securing the clamshell to the boot tray 3 Disconnect the rear harness a
458. n washer jets gutter and demist vents for transfer to the new frame Page 13 10 11 12 13 14 Lotus Service Notes Section BM If the dash baffle panel is damaged beyond in situ repair the panel must be removed by drilling out the rivets and cutting the adhesive bead between the baffle and the chassis and between the baffle and sill panels The clutch pipe main battery lead and the heater distribution cable must also be released and threaded through the panel To fit a new dash baffle Dry fit the panel and check the fit at each end to the sill panels Fettle as necessary Prepare and re activate the surface of the old adhesive on the chassis and sill panels using Betawipe 4000 see sub section BM 5 Clean and prime the bonding face on the new baffle panel using Betaclean 3900 and Betaprime 5404 see sub section 5 Apply a bead of Betaseal mate adhesive see sub section BM 5 to the baffle flange Position the panel and press along the length of the joint to ensure sufficient spread of adhesive Retain to the chassis with two rivets and clamp as necessary until the adhesive cures Primer band on chassis Dash baffle Primer band on baffle 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
459. nce Type crankshaft 47 993 to 48 000 UNIO d 47 986 to 47 993 mm Grade 47 979 to 47 986 mm Clearance bearings 0 02 to 0 05 mm Maximum out of round 0 010 mm Main joumal tolerance Type B crankshaft uranio 48 000 to 48 007 mm G ade2 ova OE ee aee 47 993 to 48 000 mm Grade a ette des 47 986 to 47 993 mm Clearance in bearings 0 013 to 0 043 mm Maximum out of round 0 010 Big end journal tolerance 1 1 1 4 and 1 6 litre Grade A rope e e Hcr eta 43 000 to 43 007 mm Grade B Louer Reel eee 42 993 to 43 000 mm Grade Git MT ute T Ra 42 986 to 42 993 mm Clearance in bearings 0 021 to 0 049 mm Maximum out of round 0 010 mm Big end connecting rod end float 0 10 to 0 25 mm Big end journal tolerance 1 8 litre Grade EE oot a ex 48 000 to 48 007 mm Grado B suse eet 47 993 to 48 000 mm GIAO yep 47 986 to 47 993 mm Clearance in bearings 0 021 to 0 049 mm Maximum out 0 010 mm Big end connecting rod end float 0 10 to 0 25 mm For commencing engine numbers for Types A and B crankshafts see Information D
460. ncluded in the tyre sidewall markings Note that the Exige wheel tyre assemblies are not approved for fitment on other Elise variants Wheelnuts Note that the wheelnuts and roadwheels on the Exige use a 60 taper and not the spherical seating used by other Elise variants It is most important that in order to maintain the highest level of safety only the approved roadwheels and nuts are used Tyres Type Yokohama A039 Size front 195 50 R16 84V LTS rear 225 45 R17 90W LTS pressure front 1 6 bar 23 Ib in rear 1 8 bar 26 Ib in heels Type Light alloy 12 spoke Size front 7J x 16 rear 8 5J x 17 ET5 Wheel nut torque 80 85 Nm 59 63 Ibf ft SSC 2000 03 ES Lotus Service Notes XIGE H STEERING All the steering components used on the Exige are as standard Elise except for the rack positioning plates which are sport specification to suit the lowered ride height The Sport removeable steering wheel may be fitted for track use For further information refer to section HE and XA EXIGE J BRAKES The Exige uses the drilled cast iron discs and brake pads as fitted to the Elise 111S For track use the motorsport brake pads front A111J0150S rear A111J0151S are recommended For further information refer to section JH IGE K COOLING The engine cooling system is unchanged from standard but all Exige models are factory fitted with oil coolers XIGE L SYST The fue
461. nd front 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 Take suitable precautions to guard against scalding Allow to drain thoroughly before cleaning the drain plug fitting a new sealing washer and tightening to 25 Nm Refill with a recommended lubricant via the oil filler on the camshaft cover to the top mark on the dipstick Be sure to remove the dipstick to permit crankcase venting and allow sufficient time for the oil to drain through to the sump before checking the oil level on the dipstick Take care not to overfill Re fit the oil filler cap securely and check the oil level again when the engine is fully warm see above Page 2 E Lotus Service Notes Section EE Oil Filter The oil filter is horizontally mounted at Oil filter the front of the engine and is accessible from beneath remove the engine bay undershield diffuser if applicable The filter should be re newed at intervals specified in the Mainte nance Schedule by turning in a counterclockwise direction using an oil filter wrench if necessary Discard the filter after removal see Used Engine Oil Before fitting a new filter clean the mat ing face on the engine and smear the new seal on the filter with clean oil Add a small amount of clean oil into the filter screw onto its spigot and tighten BY HAND just sufficiently to make a firm seal typically 2 3 to
462. nd remove the clamp ring retaining the pump assembly to the tank Withdraw the pump sender unit and sealing O ring Cap the tank aperture to prevent dirt ingress and to reduce the fume hazard 3 To release the fuel gauge sender unit unclip the black foot from the base of the canister and disengage the sender mounting bracket from the canister Disconnect the electrical cables from the unit and with draw Take care not to damage the float arm 9 Clamp ring Pump assembly end plate pr cp Y gt wre cm SE Threaded spacer ring Fuel level sender float O ring Fuel pump Sealing O ring 4 For access to the pump depress the three retaining barbs and withdraw the reservoir canister from the pump assembly Unplug the pump electrical connector and pull the pump from its outlet spigot 5 Thoroughly clean the fuel inlet strainer socks on the pump and canister before refitting Re fitting Pump Sender Assembly Before refitting the pump unit check the type of fixing screws securing the threaded ring around the tank aperture If hex head screws are fitted prior to Feb 97 replace with 10 9 grade flanged button head M4x20 screws A111W7163F with annealed copper washers A111W4170F Use Hylomar between the threaded ring and tank surface and apply thread lock to the screws before fitting with their washers and tightening to 4 0 Nm Fit the pump
463. nd suspension travel bump steer and should be measured only straight ahead at the specified ride height 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 CG 2 Track rod end flats Steering arm Steering track rod Locknut 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 80 82 Nm 58 60 Ibf 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 th
464. nd thrust washers to align drillings in carrier CAUTION Do not fit roll pin or final drive gear at this stage Torsen differential 4 Position speedometer drive gear on carrier 5 Using a suitable length of tubing drift gear fully on to carrier Standard differential 37M 1143 6 Position speedometer drive gear on carrier 7 Fit new ball bearings to carrier using tool 18G 1675 NOTE Larger of the two bearings is fitted speedomeler drive gear side MANUAL GEARBOX 0 0 Synchro Assemblies 1 Assemble each synchro sleeve to its respective hub ensuring that raised teeth on the sleeve are aligned with the deeper grooves in hub 2 Fit spring rings to retain hub NOTE Only one spring ring is fitted on Sth speed synchro 3 Assemble synchro rings to their respective sleeves CAUTION When assembling the 5th gear A synchro sleeve to hub it is possible to position the raised teeth on the synchro sleeve in the machined cut aways for the synchro ring Although the gearbox can be assembied it will not be possible to select 5th gear REVISED 12 97 OVERHAUL 19 MANUAL GEARBOX Selector Shafts 1 Slide 5th and 3rd 4th selector forks on to 5th reverse selector shaft CAUTION Ensure that longest portion of selector fork lugs face away from shoulder of shaft 2 Slide 5th reverse selector on to 5th reverse selector shaft secure selector with a new roll pin NOTE
465. nds Asafety inertia switch is mounted ahead Inertia of the ECM and controls the supply to switch the fuel pump relay Vehicle impact will trip the switch and isolate the fuel pump Reset by pressing the button on top of the switch f egulator Valve Testi The single fuel rail is used to link the four port injectors to provide a balanced fuel supply at common pressure and also to retain the port injectors in the inlet manifold The left hand end of the fuel rail receives fuel from the in line filter and the right hand end houses the pressure regulator valve from which fuel returns to the tank The fuel pressure regulator is a diaphragm operated relief valve with fuel pump pressure acting on one side of the diaphragm and regulator spring pressure and intake plenum pressure on the other The Page 20 2000 n1 Re Lotus Service Notes Section EMN function of the regulator is to maintain a constant pressure differential across the injectors at all times i e a constant difference between fue pressure supplied to the injector and inlet manifold pressure at the port injector nozzle By using an intake plenum pressure signal to supplement regulator spring pressure in the valve the valve is able to regulate fuel supply pressure in accordance with engine load The non adjustable pressure regulator is factory set to approximately 3 0 bar and is serviced as a complete assembly To check the fuel pressure i Relieve fuel pressure as detailed
466. ndscreen pillars from scrape damage before lifting the rear of the topshell and manoeuvring over the windscreen and off the front crash structure Fitment of Bonded Body Panels The cockpit tub windscreen frame side closing panels and cockpit side screens are bonded in that assembly order to the chassis and other panels using the polyurethane adhesives and techniques outlined in section BM Windscreen fitment is as described in section BN 13 Instrument Mounting Rail The curved mounting rail for the instruments is a hollow composite moulding secured to the cockpit tub with two screws at the passenger end accessible from beneath the passenger side fascia and a single screw at the driver s end For access to the latter it is necessary to remove the topshell to expose an access hole in the side closing panel 2000 02 EE Notes C PENSI The 340R is fitted with the Elise Sport suspension package which includes adjustable spring platform Koni dampers with the shorter and stiffer springs and the uprated front anti roll bar in Nylon chassis mounting blocks Standard Elise wishbones are used but are powder coated silver as are the steering arms and lower ball joint plinths Two variations of suspension geometry are specified one for road use with Yokohama or Pirelli tyres and one optimised for track use with increased negative camber and toe settings Ride height for both appli cations is com
467. ner thrust washer Outer thrust washer M16 bolt M16 Nyloc nut Flat washer Dust shee eh i gt sl Al Hub 37 Hub carrier The replacement procedure is detailed in Elise Service Notes sub section CG 4 but also note the following points a M12 bolts are handed RH thread on RH side LH thread on LH side The M16 bolts are not handed but use a higher torque setting of 210 Nm previously 77 Nm b assembly configuration is as shown in the illustration with the bolt head and dust shield on the inside and the nut on the outside Note that the plain washer is fitted between the bolt head and dust shield Page 21 Lotus Service Notes XA 10 ADJUSTABLE FRONT 111 01345 For competition use a stiffened tubular front anti roll bar 14 gauge wall thickness replaces 17 gauge is available which also provides a 5 hole choice of drop link attachment The bar is a direct replacement for the standard bar but must be used in conjunction with the Nylon block type chassis mountings not the later bonded rubber mounts introduced in March 98 For later cars discard the rubber mountings and order sepa rately the Nylon mountings and associated fixings Notes The spacer bush in the Nylon block should be fitted with the flange abutting the chassis Lubricate the bar to Nylon block using MoS grease Tighten the wishbone pivot bol
468. nes Free length 50 0 mm Fitted length 37 0 mm Load valve closed 250 12 N Load valve open 450 t 18N K16 VVC engines Free length 47 6 mm Fitted length 37 0 mm Load valve closed 210 t 13N Load valve open 440 22 ENGINE Valves and guides inspection 12M 3662 NOTE Two types of exhaust valve may be fitted standard valves A in illustration or carbon break valves B in illustration Carbon break valves may be identified by the machined profile C on the valve stem To prevent exhaust valves from sticking standard valves should be replaced with carbon break valves during engine overhaul 1 Remove carbon deposits from exhaust valve guides using tool K8 18G 1772 K16 18G 1771 CAUTION Tool must be inserted into valve guide from combustion face side of cylinder head 2 Remove carbon from inlet valve guides inlet and exhaust valves and valve seat inserts Remove all loose particles of carbon on completion 12M3663 Check existing valve stem diameters A replace any valve if stem diameter is less than specified Check inlet and exhaust valve to guide clearances C using the following procedures Insert valve into its respective guide Extend valve head 10 mm out of valve guide and position suitable gauge to rear of valve head Move valve towards front of cylinder head pre load gauge to valve head then zero gauge Move valve tow
469. ng Live Data see below may also help diagnosis This programme which requires the ignition to be switched on allows readings from various sensors to be displayed with or without the engine running This facility may also be used to observe the sensor readings whilst the car is being driven which may help to identify an intermittent problem Requesting a print will freeze the data at that instant and print out a complete list Comparison of data with a known good car may help to identify a problem Erroneous readings may be due to a faulty sensor or its associated circuitry refer to the appropriate EMN sub section or circuit diagram Engine parameters monitored include Engine rpm Manifold vacuum IAC valve position Throttle position sensor reading Coolant temperature Iniet air temperature Oxygen sensor voltage The test programme is available only on the MEMS 2J card and allows the oxygen sensor circuit to be tested and the IAC valve to be tested and reset without performing a full test programme 2000 01 E Lotus Service Notes Section EMN H D Before adjusting the cable first check that the pedal end of the cable is correctly located and that the cable is correctly routed with no sharp bends or entrapment Do not attempt to adjust the throttle cable or idle speed by means of the stop screw on the throttle body which should not be disturbed The throttle cable and associated
470. ng into differential housing using tools 18G 1354 and 18G 1354 6 37M1027 4 Fita new output sha t bearing in differential housing using tools 18G 1354 and 18G 1354 5 NOTE Depending on application output shaft bearing may have oil holes drilled in bearing these holes must face towards shaft when fitting bearing Bearings without the off hole may be fitted either wey round REVISED 12 97 OVERHAUL 27 MANUAL GEARBOX 37M 1145 CAUTION Differential oil seals Type A are fitted with early drive shafts Type B oil seals are fitted to later drive shafts The later oil seals are waxed and must be fitted dry Ensure that replacement seals are the same type as those removed Fit a new differential oil seal in differential housing using tools 18G 1354 and 18G 1354 16 Fit output shaft bearing retaining plate if fitted CAUTION Ensure side marked TOP is A facing towards output shaft 9 10 11 12 13 28 Fit 2 new Patchlok bolts to secure bearing retaining plate tighten bolts to 8 Nm Fit selector shaft and selector shaft guide Fit and tighten dowel bolt to 28 Nm Fit detent ball spring and cap bolt tighten bolt to 22 Nm Position differential assembly into housing OVERHAUL 14 15 21 Fit and tighten retaining bolts 23 24 18G 1269A 37M0178 Fit seal protector tool 18G 1269A to input shaft or apply masking tape to splines to prote
471. ng test procedure 1 Arming the System a Ensure that the front bonnet engine lid and both doors are fully closed b Open the driver s window c Press once the transmitter embossed red button if the battery has been disconnected press the button twice for a full second each time Two flashes of the turn indicators and two buzzes YES Illumination of the alarm LED constant YES 2 Door Front Bonnet amp Engine Lid Switches all actions must be within 30 seconds of arming or siren will sound Open driver s door Buzzer sounds YES b Open passenger s door Buzzer sounds YES Open front bonnet Buzzer sounds YES d Disarm system e Open engine lid f Arm system Buzzer sounds YES 9 Close engine lid Buzzer stops YES 3 Disarming the System Press once the transmitter embossed red button One flash of the direction indicators one short and one long buzz YES Alarm LED changes to flashing state YES 4 Microwave Sensor Setting and Test The sensitivity of the microwave sensor is pre set and should re quire no adjustment a Open the driver s window close all doors lids and roof and arm the system b Wait for 20 seconds before moving an arm slowly through the open window towards the gear lever Buzzer sounds YES Disarm then re arm the system and wait for 20 seconds d Wave an arm just above the roof and windscreen Page 5 GS Lotus Moies Sec
472. ngeron Luggage compartment floor Page 30 Lotus Service Notes Section 1 In order to inhibit rattles stick a length of foam rubber strip between the fixing points on the turned edge of the rear floor 2 Manoeuvre the bulkhead into position and mark the RH flange of the bulkhead against the clamshell sidewall Stick three lengths of Velcro to the RH side flange of the bulkhead and corresponding area on the sidewall and secure the bulkhead into position with three screws along the bottom edge into thread inserts in the floor front edge and two screws each side into the rear longerons Fit a single screw through the rear lid gutter into each top end of the bulkhead 3 Fitthe boot lid to the top surface of the bulkhead using 9 fasteners 4 Fitthe boot bag by securing with 5 turnbuckle fasteners to the bulkhead and hook the rim of the bag onto the clamshell gutter flange Use a spring steel U clip to retain each front end of the rim Page 31 EO re FRONT SUSPENSION SECTION CG M111 ELISE Sub Section Page General Description CG 1 3 Geometry amp Adjustments CG 2 3 Anti Roll Bar CG 3 6 Suspension Disassembly Assembly CG 4 8 Front Wheel Bearings CG 5 10 1998 02 Lotus Service Netes Section CG GENERAL LAYOUT Spring damper unit Top wishbone Steering tie rod Upper swivel joint Track rod end 73 Steering 9 K
473. nifold air leak Using the Lotus Check scanner IDLE HOTDBPOS indicates the number of IAC valve steps from fully closed 0 which the ECM has learned as the position required to maintain the specified hot idle speed STEPS shows the position of the IAC valve as calculated by the ECM based on the steps moved since the last ignition switch off This value will normally be changing during idle as the ECM continuously monitors idle speed When the ignition is switched off the ECM will keep the main relay energised for a short period whilst the IAC valve is driven to its power down position ready for the next engine start The IAC valve position may be reset using the Lotus Check tool or with the ignition on and mobilised by pressing the throttle fully and slowly 5 times Idle Air Control IAC valve Hose to intake 1754 side of throttle ee lt EL plate f Intake plenum chamber To remove the valve unplug the harness connector and remove the two Torx screws securing the valve body to the plenum adaptor Withdraw the valve and discard the O ring To fit the valve Ensure the mating faces of the plenum adaptor and valve are clean Lubricate a new O ring with silicone grease and fit to the valve Fit the valve into the adaptor and tighten the two Torx screws to 1 5 Nm Mate the electrical connector plug 2000 01 ES Lotus Service Notes Section EMN 5 The MEMS system operates a clos
474. nister fully filled An umbrella valve in the bottom of the canister allows fuel to flow into the canister whenever the tank level is higher than the canister level This feature also permits a continued fuel supply to the secondary pump stage in the event of a blocked primary stainer A removeable panel in the chassis behind the LH seat provides access to the fuel pipe connections and harness connector but if the fuel pump or gauge sender unit require attention it is necessary to remove the fuel tank from the chassis Electrical socket f cxxxxrxxxxxwux Outlet to fuel filter N N RA Return from regulator valve gt a aua qam maa Telescopic legs come Hie TE Ser iN a SS Vi il L ug Uu Fuel tank f 0 H 1 i umm Canister overflow mon n D Jesilgiluutieiat Reservoir canister DUT AUR ACA Fuel return 3rd stage turbine Fuel level float Pump motor 5 E d 2nd stage impellor f 1st stage impellor 2nd stage strainer uc 1st stage strainer Umbrella valves a To Remove Pump Sender Assembly 1 Remove the fuel tank see sub section LH 5 2 Release the 8 x 5 fixing nuts noting that the unit is lightly spring loaded a
475. nput Before energising the compressor clutch the ECM first adjusts the idle air control valve to compensate for the increased engine load Compressor switching will be inhibited under certain conditions including engine cranking wide open throttle excessive coolant temperature Cooling Fan Control Elise Elise models with a c are fitted with two radiator fans one switched by the engine ECM on the basis of coolant temperature as for non a c cars with the second fan switched via the a c request push switch Cooling Fan Control Exige Exige models with a c are fitted with two radiator fans controlled by the engine ECM and a relay module mounted in the front services compartment and operate always as a pair either off switched in series for half speed operation switched in parallel for full speed operation Under normal conditions the fans operate only at vehicle speeds below 25 mph 40 km h When coolant temperature reaches approx 102 C the fans operate at half speed with full speed operation switching in if coolant should reach 108 C When the trinary switch on the receiver drier indicates that a c is operating and that condenser cooling is required the fans will operate at fast speed regardless of coolant temperature Engine Malfunction the engine ECM detects certain types of engine malfunction including misfire or anomolies in coolant temperature or intake air temperature the cooling fans will be switched
476. nspect steering ball joints amp gaiters Inspect free play at steering wheel 1 service table sn_og_t2 eps 2 2 2 2 3 5 Continued 1998 03 5 Lotus Service Notes Section SERVICE OPERATION DESCRIPTION A B C rera Sales intervals Wheels amp Tyres 27 Inspect tyre condition amp set pressures ixixix x Electrical Check battery terminals for security amp condition Inspect operation of all lights 30 Inspect operation of all electrical equipment 3 1 33 Top up screenwash reservoir 34 Renew alarm transmitter batteries check with customer Road Test Performance Engine performance T ilpipe CO cS TR RR ere Clutch Operation o eeaeee Gearbox operation Brake performance Steering performance Driveline amp suspension noise vibration Wheel balance General commienhts eaaa ai Eesaia iaa E Additional Work a eae Spa I EES EEE A ETELE TRE Work completed Dealer stamp Recommended Service Times After Sales Service 1 3 hr A Se
477. nsuitable 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 remove old adhesive as necessary until the fit is satisfactory Re acivate the surface of the old adhesive on the chassis using Betawipe 4000 see sub section 5 and clean and prime the bonding area on the new crash structure using Betaclean 3900 and Betaprime 5404 see sub section BM 5 Bonding surface on chassis Composite crash structure 6278 11 E Lotus Service Notes Section BM Application of adhesive bead Betaseal bead Apply a bead of Betaseal mate adhesive see sub section BM 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 KF 4 front clamshell s
478. o steering arm 55 Lower swivel joint to plinth 55 Lower swivel joint plinth to hub carrier 45 Steering arm to hub carrier 45 Track rod end to steering arm 30 Damper to lower wishbone 45 Damper to chassis 45 Brake caliper to hub carrier 45 Anti roll bar rubber bush mounting clamps 20 Anti roll bar drop links 45 CG 5 FRONT WHEEL BEARINGS A sealed dual taper roller bearing with a split inner race is retained in each front hub by two circlips The hub is pressed into the bearing and retained by a clamp bolt which also applies the necessary preload to the bearing assembly Check for any discernible free play in the hub bearing and for any signs of lubricant expul sion indicative of seal failure If free play is evident or any roughness or tight spots can be felt the bearing should be replaced there is no provision for adjustment Note that removal of the front hub will normally result in separation of the hub bearing inner race necessitating renewal of the bearing Front Hub M16 Clamp Bolt Set Standard cars used front hub M12 clamp bolt set until Sept 1997 approx VIN W 1830 at which time the competition type M16 clamp bolt set was commonised to all cars If an early car is to be used in a competition environment with the associated high level of chassis loading it is recommended that the front hub bearing M12 clamp bolts be replaced by M16 clamp bolt sets including thrust washers which allow a substantial increase in the clampin
479. oard driveshaft is splined into the hub A nut on the end of the driveshaft both retains the shaft in the bearing and applies the necessary preload to the bearing assembly Check for any discernible free play in the hub bearing and for any signs of lubricant expulsion indicative of seal failure free play is evident or any roughness or tight spots can be felt the bearing should be replaced Note that removal of the rear hub will usually result in separation of the hub bearing inner race necessitating renewal of the bearing To Replace Rear Hub Bearing Note that removal of a rear hub Replacement of the hub bearing is most easily performed with the hub carrier removed to a bench Bearing circlips IN PX 22 Rear hub EEGENEN lt gt Outboard driveshaft 22 ORO 1 Hub nut Hub carrier Hub bearing 925 1 With the wheel removed apply the parking brake and release the driveshaft to rear hub nut Removal of the nut can be eased by using a punch to knock the distorted end of the nut clear of the driveshaft slot 2 Removethe two bolts securing the brake caliper to its mounting bracket and support the caliper clear of the disc without straining the flexible hose or parking brake cable Withdraw the brake disc from the hub 3 Remove the wheel speed sensor from the LH hub carrier to prevent damage during driveshaft removal 4 Remove the two bolts securing the top swivel
480. ocation The alarm system components are located as follows Electronic Controller Mounted on the top of the scuttle beam above the passenger footwell Some accessibility is available via the audio set aperture Siren Unit Mounted on the passenger side of the scuttle beam Immobiliser Module Mounted in the electronics box on the cabin rear bulkhead Intrusion Sensor Stuck to engine ECM bulkhead electronics box The tailgate sensor switch is mounted at the rear of the lid aperture alongside the latch The front bonnet sensor is mounted at the rear of the aperture alongside the latch Intrusion microwave sensor H Tailgate sensor Tell tale Front bonnet sensor Em Electronic controller Siren unit Immobiliser module Door SSC 2000 03 Lotus Service Notes Exige AUDIO EQUIPMENT All cars are fitted with a standard Elise amplifier type aerial mounted on the roof air duct and wired to a connector plug behind the fascia The factory option of an audio fitting kit comprises a pair of Speakers mounted in the rear bulkhead and wired to a 16 pin ISO connector behind the fascia Cars built without this option retain the speaker wiring but have blanking panels in place of speakers Due to packaging restraints Exige speakers are smaller than those in the Elise and are common with Esprit fascia speakers with 100mm diameter 50W peak 15W RMS 2000 03 fina a Fuses amp Relay
481. od into or out of the trunnion until the pedal just contacts the pedal box flange upstop iii Apply turn of preload to the pushrod and tighten the trunnion lock screw to 5 Nm Clutch pedal Pushrod to master cylinder Trunnion Trunnion grub screw 1009 N9 Paae 3 4 Lotus Service Notes Section Note that no pedal downstop is fitted and that the pedal will contact the pedal box before the master cylinder bottoms out Adjusted as above full pedal travel should produce a slave cylinder pushrod movement of 13 15 mm If this is not achieved bleed the hydraulic system using new DOT 4 non mineral type fluid Note that the alloy trunnion in the pedal is Zylan coated to provide maintenance free lubrication although silicone grease is used on initial assembly QF 3 HYDRAULIC RELEASE SYSTEM Master Cylinder The 5 8 15 9 mm bore 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 Input pushrod Pedal box Brake master cylinder reservoir e Fluid reservoir hose Outlet pipe Fixing nut Clutch master cylinder 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 contaminati
482. oil seals are coloured RED CAUTION Oil seals must be fitted dry Do not use tool 18G 1769 for fitting seals as they will not be positioned correctly within recess 18 1604 77244244442 M12 7255 19 Fit new front and rear VVC housing oil seals using tool 18G 1604A NOTE Front oil seals are coloured A BLACK rear oil seats are coloured RED CAUTION Oil seals must be fitted dry Do A not use tool 18G 1604 for fitting seals as they will not be positioned correctly within recess OVERHAUL 65 ENGINE 12M3505 20 20 Fit rear timing belt backplate fit and tighten bolts to M5 bolts 6 Nm M6 bolts 10 Nm 12 3506 21 Ensure that hydraulic control piston is pushed fully to top of bore and that rack teeth will be aligned to control shaft when control unit is fitted 22 Position hydraulic control unit and seal plate to camshaft carrier engage teeth of rack with those of control shaft 23 Fit and lightly tighten 3 bolts OVERHAUL 12M3507 24 Check that timing slots in front and rear VVC control sleeves are visible through holes in camshaft carrier CAUTION If timing slots are not visible A carry out following procedure 25 Remove hydraulic control unit 12M3524 26 Using a screwdriver rotate control shaft as far 29 Check that timing slots on both front and rear as possible in an anti clockwise direction VVC control sleeves are visible If slots are still viewe
483. om the chassis using a suitable cutting knife Cut the sealant around the door hinge post aperture and the striker plate 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 Cut the flange from the sill to match the windscreen frame buttress cut out made during removal Dry fit the sill and fettle as necessary to achieve a good fit Page 16 Section BM Button head fixing if fitted Bonding path Chassis rail upper amp lower slots Sill panel 7 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 feed and return pipes if fitted LH side heater return pipe clutch pipe main battery positive cable 8 Prepare the bonding surface of the new sill panel with Betaclean 3900 and Betaprime 5404 see sub section BM 5 Prepare surface of the old adhesive bead on the chassis and body panels using Betawipe 4000 see sub section BM 5 9 Apply a bead of Betaseal mate adhesive see sub section BM 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
484. on Lotus does NOT recommend that the Elise is subjected to a mechanical automatic car wash as some types of brushes used in these devices may cause scratching of the flexible rear window and accelerated ageing of the roof fabric The car should be hand washed using the following instructions General Many contaminants are water soluble and can be removed before any harm occurs by thorough washing with plenty of luke warm water which includes a proprietary car wash additive household detergent can remove wax and accelerate oxidation Frequent washing is the best safeguard against unseen contami nants at the same time ensuring the regular removal of dirt dust and traffic film Wash in the shade and use a cotton chenille wash mitt or a sponge rinsed frequently to ensure no entrapment of dirt particles Use a straight back and forth washing motion to avoid swirled micro scratches and rinse thoroughly Soft Top Roof 1 Careful vacuuming of the soft top before washing may be helpful in removing excess dust and other foreign particles Wash in partial shade rather than strong sunlight and wet the whole car before tackling the soft top Use a sponge a chamois or cloth will leave lint and a brush may abrade the threads to apply a mild soap solution of lukewarm water Do NOT use a detergent 4 To avoid rings or spots wash the entire top uniformly and let the soapy solution remain on the fabric for 2 to 5 minutes 5 Rinse the whole car to
485. on from the cam belt 4 Use special tool T000T1280 to hold the inlet camshaft pulley and release the retaining bolt Withdraw the pulley from the camshaft and timing belt 5 Fitthe new pulley to the camshaft with the T mark just above the timing mark on the exhaust camshaft pulley and the dowel engaged in the pulley slot Use special tool TO00T1280 to hold the inlet camshaft pulley and tighten the M10 retaining bolt to 65 Nm 6 Turm the inlet camshaft to align the inlet pulley T mark with the exhaust pulley EXHAUST mark and slip the belt onto the pulleys ensuring that the drive side of the belt is tight and the crankshaft pulley is still positioned at the 90 ATDC mark 7 Using a 6mm hex key rotate the tensioner counterclockwise and align the centre of the indent on the tensioner pointer with the index wire ensuring that the pointer approaches the index wire from above If the pointer passes the wire release the tension completely and repeat the procedure 8 Ensuring that the pointer does not move tighten the tensioner bolt to 25 Nm 9 Using the crankshaft pulley bolt slowly turn the crankshaft 2 turns clockwise to check there is no valve piston contact and re align the timing marks without having to back up Check that the tensioner pointer is still correctly aligned with the index wire If not slacken the tensioner bolt until it is just possible to move the lever clockwise and position the pointer just above the index wir
486. on machined edge of oil feed channel Push piston to top of bore OVERHAUL 59 ENGINE M12 7254 10 Lubricate 3 new O nngs with engine oil and fit to spool valve 11 Lubricate new O rings with engine oil and fit to each side of spool valve nut washer inner solenoid and sleeve bolt side of outer solenoid 12 Lubricate spool valve and bore in control unit with engine oil 13 Position spool valve to control unit fit valve twisting it slightly as it is inserted to avoid damaging O rings 14 Tighten spool valve nut to 26 Nm 15 Position inner solenoid on spool valve ensuring that lettering on end of solenoid is facing away from control unit 16 Fit washer and O ring 17 Position outer solenoid on spool valve ensuring that lettering on end of solenoid is facing away from control unit 18 Position inner and outer solenoids as shown fit nut to sleeve boit and tighten to 12 Nm CAUTION Do not exceed specified torque figure 19 Retain oil temperature transmitter with control unit plug oil temperature transmitter port to prevent ingress of dirt 60 OVERHAUL Valves assembling 1 Using 18G 1577 fit new valve stem oil seals 2 Lubricate valve stems and assemble valves using tool 18G 1519 and adapter 18G 1519 1 to compress valve spring CAUTION Valve springs are either colour coded or plain ensure correct springs are fitted K8 Yellow red K16 Non VVC engines Plain K16
487. on 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 vers 1998 02 Lotus Service Notes Section QF To overhaul the master cylinder Clamp the cylinder in a soft jawed vice and pull the rubber dust boot off the cylinder end Remove the circlip from the end of the cylinder taking care not to scratch the bore surface Remove the stop washer and extract the cylinder internal parts Lay the components in their correct order on a clean sheet of paper Remove the rubber seals from the piston taking note of the position and orientation of all parts Clean all parts thoroughly with only new brake fluid and dry with a lint free cloth Carefully examine the cylinder bore for scoring corrosion or visible wear and replace if any such signs are apparent Check that all drillings in the cylinder body and piston are clear If the cylinder is serviceable rebuild the unit using new seals and components from the appropriate overhaul kit Note that the cha
488. open and close periods by independent positioning of the two inlet camshaft assemblies thereby giving optimum low speed driveability with no detriment to high speed performance DESCRIPTION AND OPERATION 17 ENGINE Whilst the exhaust camshaft is similar to camshafts fitted to non VVC K16 engines there are four inlet camshafts assembled in pairs each individual camshaft operating the inlet valves on one cylinder The front pair of camshafts are driven via the front VVC mechanism by the camshaft timing belt the rear pair of camshafts being driven via the rear VVC mechanism by the rear timing belt which is itself driven by the exhaust camshaft Independent positioning of each inlet camshaft is controlled by its respective VVC mechanism The front and rear VVC mechanisms are connected to each other by the control shaft Movement of the control shaft is controlled by the piston and rack assembly located within the hydraulic control unit The piston and rack assembly moves in response to engine speed and load signals received from the MEMS ECM via two solenoids mounted on the hydraulic control unit housing As the piston and rack moves up or down in response to the signals received the control shaft rotates and alters the position of the valve timing mechanisms All engines Self adjusting hydraulic tappets are fitted on top of each valve and are operated directly by the camshaft s The valve stem oil seals are moulded onto a me
489. operation 2 Carefully withdraw the fluid reservoir spigots from the master cylinder grommets 3 Remove the pushrod boot and the front piston stop bolt and washer 4 Using a rounded end mandrel press the rear piston into the cylinder sufficiently to relieve load on the cylinder end circlip Remove the circlip and stop washer and carefully remove the pistons and springs from the cylinder If necessary knock the cylinder against a wood or plastic surface to extract the front piston assembly Reservoir port Stop sleeve Rear piston Front piston Circlip E 0am SCC 02222520 066 E aS MEME aao eu 7 G E LE J NN Stop sleeve retaining screw Outlet ports Outlet to rear to front circuits circuit Page 10 CS Lotus Service Notes Section Press the stop sleeve against the rear piston and release the screw retaining the sleeve Remove the stop sleeve screw spring and spring seat washer Carefully remove the primary seal and grooved seal from the rear piston From the front piston remove the primary seal and the two secondary seals Thoroughly clean the cylinder bore inlet and outlet ports and all component parts using brake cleaning fluid or alcohol and blow dry with compressed air Carefully inspect the master cylinder bore for scoring and corrosion Any more than the slightest signs of either of these effects indicates th
490. or and will range from 0 closed to 255 fully open The full range of values will not be seen in practice Throttle Switch indicates whether the ECM detects an open or closed throttle If the display reads ON when the throttle is closed the engine will not idle correctly and the closed throttle position may need to be reset Run a or TEST programme to reset To remove the sensor unplug the harness connector and remove and discard the two Torx screws secur ing the sensor Remove the clamping plate and withdraw the sensor from the throttle spindle To fit the sensor Clean the mating faces of sensor and throttle body and align the flat of the sensor with the machined flat on the throttle spindle CAUTION The TP sensor can be easily damaged if carelessly fitted When pressing the sensor onto the spindle use only finger pressure on the centre of the sensor Do not use the securing screws to pull the sensor into position Press the sensor into position and rotate counterclockwise to align the fixing holes CAUTION Do not rotate the sensor in a clockwise direction and ensure it is not rotated beyond its internal stops Fit the clamping plate and tighten two new Torx screws Mate the harness connector plug Operate the throttle and check that full travel of the throttle spindle from fully closed to fully open is achieved 2000 NI Page 13 EG Lotus Service Notes Section EMN The idle air control IAC valve
491. or 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 alarm when triggered disarm as described below Disarming the Alarm To disarm the alarm prior to entering the vehicle or if the alarm has been triggered press once the button on the transmitter key This command will be acknowledged by One flash of the hazard warning lamps Extinguishing of the alarm tell tale ahead of the gear lever If the alarm had been triggered during the last armed period the alarm tell tale will light and off blink a code s for about 30 seconds to indicate which of the triggers was responsible 4 blink offs every 6 seconds engine lid or front access panels 8 blink offs every 6 seconds ignition input 1 blink off every 6 seconds microwave sensor This coding will be repeated each time the alarm is disarmed until the memory is cleared by pressing the transmitter button with the ignition switched on Intrusion Sensing A microwave sensor is mounted in the rear bulkhead electronics compartment and INTRUSION is able to detect substantial physical move SENSOR ment within the cockpit and trigger the alarm The range and sensitivity of the intrusion sen sor may be adjusted if necessary by turning an adjuster screw on the unit If desired t
492. or less the supervisor is advised to apply for a new password which cannot be done before this time Application for a second and subsequent supervisor passwords is made via the Password Renewal form which should be completed and faxed to Omitech Instru mentation together with a printout from the Gei Up menu which is required for security data analysis A small administrative charge will be made for the second and subsequent passwords System Check Not applicable on Cobra cars This may be selected from the main menu in order to check the operation of the door switches and immobilisation system Select Level 2 from the subsequent menu and follow the instructions displayed on the scanner Note Disarming alarm using key access codes transmitter Key access codes not applicable to the Elise Disarm using the transmitter ECM Matching This facility is available from the Set Up User menu and is required if either a MEMS 1 9 ECM or 5AS Security ECM is replaced The 5AS module sends a coded signal to the MEMS module in order for the immobilisation feature to operate and if either module is replaced the MEMS module must be programmed to recognise the signal Note that the last eight digits of the Vehicle Identification Number are required to be entered but that the third of these digits is called for as an alpha character rather than the actual numeric For this purpose disre gard the third character Transmitter
493. or rear vision a front apron splitter set at road height and a revised rear aerofoil to provide the required aerodynamic balance Elise sport suspension uses model specific calibration in com bination with specially developed Yokohama A039 tyres Page 2 _ EG Lotus Service Notes Exige EXIGE TD TECHNICA TA Tyres Size front rear pressure cold front rear Wheels Type Size front rear Wheel nut torque Dimensions Overall length Overall width Overall height at kerb weight Wheelbase Track front rear Ground clearance at kerb weight Front overhang Rear overhang Untaden weight total front rear Maximum weight total front rear Trailer towing Capacities Engine oil refill inc filter High low dipstick mark difference Transmission oil Fuel tank Cooling system Front Suspension Type Ride height for geometry check front rear Steering axis inclination Castor Camber Alignment 2000 03 Yokohama A039 195 50 R16 84V LTS 225 45 R17 90W LTS 1 6 bar 23 Ib in 1 8 bar 26 Ib in Light alloy 12 spoke 7 16 8 5 17 5 80 85 Nm 59 63 Ibf ft 3761 1730 1201 mm excl aerial 2300 mm 1457 mm 1476 mm 155 mm 774 687 mm 785 kg 319 kg 466 kg 1012 kg 427 kg 585 kg Not permissible inc full fuel tank incl occupants amp luggage 4 5 litre 7 9 imp pt 1 0 litre 1 8 imp pt 2 1 l
494. or the tailgate is mounted in the rear end of the roof duct and the standard Elise aerial is mounted on the top of the duct The roof panel is retained in a similar manner to that used on standard car hard tops but has an extended rear flange which underlaps the forward edge of the rear clamshell The roof may be removed with the clamshell in situ but requires that the rear clamshell front fixings be released To remove the roof panel remove the tailgate from the hinge or the hinge from the roof disconnect the aerial lead 2000 03 id 3 Lotus Service Notes Exige release the fixings securing the top front corners of the rear clamshell to rear bulkhead remove the header rail clamp from inside the front of the roof release the over centre latches clamping the rear of the roof to the upper rear bulkhead and lift off the roof panel Tailgate The tailgate panel comprises a clear polycarbonate moulding bonded to a composite reinforcing sur round and with an air intake exit duct incorporated into a spinal feature A single hinge is mounted inside the roof air duct and a new latch mechanism is mounted on a plinth at the rear of the clamshell aperture with a loop type striker fixed to the tailgate The existing cable release mechanism with stainless cable is utilised The polycarbonate screen is hard coated on both inside and outside surfaces and should be cleaned using normal car wash preparations Aerosol type
495. orner of the panel calibrated in the same units as the speedometer order to zero the trip display switch on the ignition and press for a moment less than 1 sec ond the small button on the steering column shroud between the ignition switch and steering wheel This dual function button also controls the panel illumi nation see Instrument amp Switch Illumination FASCIA SWITCHES Trip reset button ESCH Sidelamp Switch A green tell tale window within the switch button is back lit when the ignition is switched on to help locate the switch Pressing the switch will switch on the sidelamps and panel illumination and brighten the switch button tell tale The switch operates with or without ignition Press a second time to switch off Master Lighting Switch A green tell tale window within the switch button is back lit illuminated when the ignition is switched on to help locate the switch Pressing the switch which operates with or without ignition will switch on the head lamps in addition to the sidelamps and panel illumination irrespective of the sidelamps switch position The switch button tell tale brightens when the switch is pressed Press a second time to switch off Rear Fog Lamp Switch Sidelamps Rear Foglamps Spare An amber tell tale in the switch button is back lit when the sidelamps are switched on in order to help locate the switch A single fog guard lamp is fitted on the offside rear of the car and is operative
496. osed bolt length Specification 21 0 to 25 0 mm If either of these dimensions is outside tolerance change either the bolt length or the washer be neath the bolt head but do not alter the shim pack If the shim pack detail is lost refer to Serv ice Notes sub section XA 8 to cal culate the shim pack thickness A Ifthe original bolt is to be refitted thoroughly clean the bolt thread using a wire brush Degrease and dry If a new bolt is to be fitted degrease and dry the bolt thread Fit the bolt with washer through the hub carrier conical spacer and shim washer stack Shank protrusion EE 1 0 to 9 0 mm 1999 01 i Exposed bolt length 21 0 to 25 0 mm M10x60 or M10x65 bolt Flat washer SPESE NUN Hub carrier R EX CN Conical spacer CA Ip Shim stack N 5 NEN Permabond A134 SEN applied to thread SEEN Toe link outer ball joint WS lt d32 Page 9 Lotus Service Notes Section DE 5 Apply Permabond A134 to the whole of the bolt thread from tip to shank Applying threadlock before insertion of the bolt Permabond A134 may glue the bolt into the carrier A100B6155V 9 Thread the bolt into the ball joint and torque tighten to 45 Nm 615 Assembly procedure toe link inboard fixing early type joint 1 Use a proprietary degreaser e g Silkolene Contact Cleaner to degrease the female thread in the ball joint checking that the bottom of the hole is not restricted
497. osues dVIN eJnsseJgd DOUUEW Hoas uunnoeA Josues peeds PIYA yoed uoniub 10 jeuosa Josues 41 uonisod ayo 1033002 ap E L 02 6 SL 4 9 Sh 913 soyeinGas ainssaud jon J Joyoefui jon J Josues IYW ary Josues yeysyuesD Josues ueB xQO jepues 1 10sues 193 3uejoo W93 2tuonooera Joy feng Jejsiueo 51 eAgeJodeA orn rere KNOT HON DO Page 11 LS Lotus Service Notes 340R Engine Management The engine management electronic controller is common with the Esprit V8 and uses some of that model s components including Idle Air Control IAC valve mounted on the rear of the engine and connected by hose between the intake airbox backplate and ports in the underside of each inlet manifold tract Ignition Coil Pack one of the two identical V8 coil packs mounted on the rear of the cylinder head Electronic Control Module ECM mounted on the cabin rear bulkhead controls engine management systems including fully sequential injection and direct ignition Manifold Air Pressure MAP and Barometric pressure BARO sensors mounted on the engine bay LH wall Other engine man
498. ot of the primary scissor arm and the door shell 7 Aneccentric stop is fitted to the top end of the toothed sector to limit the upward travel of the glass and slotted fixing holes for the reaction channel allow for some adjustment to the top edge tilt to be made 1898 01 E Lotus Service Notes Section BN Check that a metal gauze friction washer is fitted between the eccentric stop and the toothed sector before checking the glass position Erect the soft top roof and raise the door glass to assess the fit of the glass against the roof and A B post seals If necessary adjust the eccentric upstop and the reaction channel fixing position and or the glass guide channels see below to achieve a light contact between the whole of the glass edge and the seals Door glass guide channels The front guide channel is secured by two screws through the bottom face of the door shell into captive spring steel nuts on the channel bottom flanges and by a single countersunk screw at the top end into a captive M5 nut in the mirror mount area This top screw is covered by the guide channel insert silent channel Note that the front guide channel is positioned in the door during manufacture and cannot readily be removed Any adjustments to door glass inward tilt can be accommodated by moving the lower end of the rail as required Cheater seal uid Chanel NS i top fixing cs Front channel lower fixing gea 1998 01
499. otes Section MN 1 the transmitter case using a finger or blade in the case jointline 2 Slide the battery out of its keeper and insert the new taking care to match the polarity marking 3 Snap the case halves together Lucas 5AS module Instrument pack 5AS module mounting bracket Steering column 183 The 5AS module is mounted behind the fascia on the steering column upper bracket and may be accessed after removal of the column shrouds and instrument pack see sub section BN 12 For diagnosis of alarm system faults see sub section MN 2 Upgraded Vehicle Security Alarm Cobra Goldline 6019HF The optional upgraded vehicle alarm includes the following security features Ingress protection using sensing switches on the front bonnet engine lid and both doors Switchable intrusion sensing in the passenger compartment using a microwave sensor Self powered siren for strident warning even if the vehicle battery supply is interrupted Passive engine immobilisation after 60 second delay Dynamic changing coding of the transmitter key to minimise the possibility of code copying Passive Immobilisation Engine cranking and running are disabled automatically 60 seconds after either the ignition is turned off the alarm is disarmed A warning that immobilisation is in effect is provided by the Alarm tell tale in the instrument pack lighting steady In order to mobilise the engine press once the
500. ous Seats Remove the passenger seat and mounting frame Remove the driver s seat but retain the runners Driver s 5th point seat harness kit Remove the latch from the seat harness lap strap by inserting a stiff wire into the latch hole By similar technique fit the new rotary release latch to the lap strap Fit the grommet onto the new crutch strap and thread the anchor bar through the crutch strap loop Feed the strap through the seat frame cross brace aperture and the slot in the new carbon fibre driver s seat and fit the grommet into the frame aperture Fit the new seat to the runners with the crutch strap anchor bar secured beneath the cross brace by the seat front fixings Roll over bar Remove the double hoop roll over bar and replace with the driver only RAC approved RHD or Page 38 Lotus Service Notes Section XA LHD bar This will require a clearance slot to be made in the engine lid and body aperture gutter A template LSL401 for the engine lid slot is provided with the bar to allow an initial fit to be made with initial dimensions for the body aperture measureable from this The spoiler mounting plate will also require a small clearance groove to be made to allow the backstay to be connected The body on each car will require individual fettling but with care no painting should be required Note that with this bar fitted a passenger seat MUST NOT be fitted Removable steering wheel Fit the removable steering wheel kit as d
501. ow the adhesive to fully cure and cut away any excess using a scalpel blade 13 Use duct tape and or support blocks to hold the screen in position and do not disturb until the Betaseal is fully cured This will take approximately 4 hours dependent on atmospheric conditions with a longer period required in dry atmospheres Cartridge nozzle Betaseal bead Obscuration band Primer band Edge finisher NE Bead along centre of primer band A gt Spacer block in inside edge of bead 14 Remove the tape and refit the wiper arm and interior mirror Spillage of material a spillage of Betaseal onto unprimed glass can be readily peeled off after it has cured b spillage onto the body can be removed with either Wipe Cleaner No 4 or white spirit Page 27 Lotus Service Notes Section BN Shelf life Betaseal primer has a useful life of only about 24 hrs after it has been exposed 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 BN 14 ROOF HEADER RETAINING STRIP To retain the front of the soft top roof an aluminium tongue strip is fixed to the top of the windscreen header rail via a moulded plastic carrier A textured gripper strip is applied to the top of the ton
502. part of the fuel line except the unpressurised return line Fuel Fuel pump pump fuse fuse Pull out the fuel pump 20A fuse see above start the engine and run until it stops from starvation Crank the engine for a further 10 seconds If the engine is a non runner pul out the fuel pump fuse and crank the engine for a total time of 60 seconds to minimise residual fuel pressure Disconnect the battery Use a shop towel to absorb the small amount of pressurised fuel remaining as a fuel feed pipe connection is released and dispose of safely The modular fuel pump sender assembly uses an electric motor to power a three stage impeller type pump system submerged within the tank In order to avoid fuel starvation from surge effects caused by vehicle acceleration and cornering forces the pump is housed within a reservoir canister kept filled with fuel irrespec tive of the tank fuel level The pump connects with a port on the bottom of the canister fitted with a strainer sock in order to screen dirt particles from the fuel line and help separate any water content from the fuel The first stage impeller pump draws fuel from the tank via this sock and outputs it into the canister which fills up to its overflow port in the top surface The second stage impeller pump draws fuel from within the canister via another strainer sock and supplies the high pressure third stage tubine pump which outputs fuel from the top end of the pump into the flexibl
503. pecification 80 1mm 2 Inner Column Lower Measure the length of the exposed part of the inner column as shown Specification 58 1mm Page 5 Lotus Service Notes Section HE Outer column column 9 FTO lower end o sr 80 x 1 mm 58 1 mm E 3 Inner Column Upper With the steering wheel removed measure the length of the exposed part of the upper column as shown Specification 76 x 1mm Inner column upper end 524 Alloy break out insert 4 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 To Remove er Steering Column Assembl 1 Disconnect the battery and remove the column shrouds see sub section HE 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 3 disconnect the ignition switch prise open the terminal cover and use a small screwdriver to release 2 22 22 cU C R EEN Page 6 10 11 Lotus Service Notes Section HE the retaining barb located between the white and yellow cables Withdraw the connector If necessary remove the steering lock ignition key barrel Turn the key to position l depress the
504. pecification change Revised Harness amp Main Fusebox October 97 VIN W 1941 onwards Plus 1920 1926 1937 1938 Less 1965 2002 New harness introduced to accommodate optional U K market Cobra 6422 alarm New main fusebox with 22 Littel fuses in front luggage compartment Optional U K Market Cobra 6422 Alarm October 97 VIN W 1947 onwards Plus 1937 1938 Option upgraded from Cobra 6019HF to 6422 Facility to reprogramme transmitter keys Override switch deleted Front Brake Disc Shields December 97 VIN W 2260 approx Alloy shield fitted on inboard side of front discs to protect from debris and balance pad life Revised Soft Top Cant Rails May 98 VIN W 3332 Latches on rear end of roof cant rails use new dovetail design to improve location Door seals changed to incorporate moulded front ends to mate with new cantrail front seals New soft top canopy with press studs reposiitioned to suit new cant rails Parts set required to fit hardtop roof Cast Brakes June 98 VIN W 3714 approx Cast iron brake discs and corresponding pads replace aluminium metal matrix brakes Integral Boot Box September 98 VIN W 4429 approx Plus 4140 4315 4365 4383 Less 4653 Rear clamshell incorporates integral luggage compartment box to replace luggage bag 1999 Model Year November 98 VIN X 4976 onwards No specification change 2000 03 Lotus Service Notes Introduction 135 Sport November
505. peed and MAP signals with the current period measured by the cam position sensor To replace the solenoids Unplug the harness connectors Release the adjacent breather pipes and harnesses to provide access to the sleeve nut Remove the nut and slide the two solenoids off the spool valve shaft taking care not to misplace the O rings and spacer When refitting lubricate all O rings and spool valve shaft with engine oil and note that although the two solenoids are identical the correct harness plug must be connected to each black to RH solenoid blue to LH solenoid Assemble onto the spool valve shaft in the following order O ring One solenoid with lettering on end surface facing away from HCU Spacer with O ring fitted Second solenoid with lettering on end surface facing away from HCU End nut with O ring fitted Position solenoids to allow connector plugs to be fitted before tightening nut to 12 Nm Hydraulic control unit HCU Spool valve shaft Connect black harness plug to solenoid valve End nut O ring on spacer washer Connect blue Lesen harness plug to solenoid valve O ring End face lettering 2000 7 nt Page 17 Lotus Service Notes Section EMN E An oil temperature sensor is mounted in the top of the VVC hydraulic control unit The oil temperature is used by the ECM to determine how quickly the VVC mechanism will respond to cam period change com mands
506. perature sensor Bolt coolant outiet elbow Hydraulic tappet Valve spring cap Valve spring Valve stem oil seal Collets Locating dowel Cylinder head Gasket cylinder head Exhaust valve guide Valve seat insert exhaust Exhaust valve Valve seat insert inlet Inlet valve Inlet valve guide Bolt cylinder head Bolt camshaft carrier DESCRIPTION AND OPERATION 9 ENGINE M12 7257 10 DESCRIPTION AND OPERATION ENGINE 2222 CYLINDER HEAD COMPONENTS K16 VVC ENGINES Bolts hydraulic control unit Hydraulic control unit body and spool valve Solenoids O rings Spool valve nut Oil temperature transmitter Piston screw piston and seal assembly Rack Seal plate Labyrinth seals Spark plug Spark plug cover Oil filler cap Filler cap seal Screw spark plug cover Washer Bolt camshaft cover Camshaft cover Gasket camshaft cover Bolt camshaft carrier Camshaft carrier Control shaft Rear VVC housing and mechanism Gasket VVC housing Bolt VVC housing Rear inlet camshaft Front inlet camshaft Early engines Later engines Front VVC housing and mechanism Exhaust camshaft oil seals Exhaust camshaft Gasket coolant outlet elbow Coolant outlet elbow Sealing washer Gasket Coolant temperature sensors Bolt coolant outlet e
507. poses journal sizes on crankshafts fitted to early engines are listed as Type A whilst those fitted to later engines are listed as Type B Main bearing shell sizes and colour codes for both types of crankshaft remain unchanged 7 Check crankshaft main journal diameters ENGINE 2292 Type crankshafts Crankshaft journal tolerance Grade 1 47 993 to 48 000 mm Grade 2 47 986 to 47 993 mm Grade 3 47 979 to 47 986 mm Clearance in bearings 0 02 to 0 05 mm Maximum out of round 0 010 mm Type B crankshafts Crankshaft journal tolerance Grade 1 48 000 to 48 007 mm Grade 2 47 993 to 48 000 mm Grade 3 47 986 to 47 993 mm Clearance in bearings 0 013 to 0 043 mm Maximum out of round 0 010 mm 8 crankshaft if outside tolerance 9 Determine the appropriate bearing shells to be fitted from the main bearing size selection and type tables OVERHAUL 83 ENGINE 84 OVERHAUL ENGINE 2298 Main bearings selection Main bearings size selection table Crankshaft main journals BLUE BLUE RED BLUE RED RED BLUE GREEN BLUE BLUE RED BLUE GREEN GREEN BLUE GREEN BLUE BLUE Colour code on edge of bearing Thickness progression Bearing ladder GREEN Thin BLUE Intermediate RED Thick CAUTION If two bearing colours are to be used thicker bearing must be fitted to bearing ladder When original crankshaft is to be refitted bearing shells must b
508. position 11 is not operative iii Press the accelerator pedal to one quarter travel approx 25mm and turn the key against spring pres sure to position Ill to engage the starter motor As soon as the engine starts release key pressure and adjust the accelerator position to maintain 2 000 rpm for 10 seconds to minimise emissions iv If the engine fails to start within 15 seconds stop cranking and pause for 10 seconds before a second attempt If further efforts are unsuccessful increase throttle opening to half way and repeat v _ If the engine still fails to start it is likely that it will have become fuel flooded Provision is made to cut off the fuel supply completely when cranking by fully depressing the accelerator Repeat the starting proce dure holding the pedal fully down and release immediately the engine starts Idle Speed Engine idle speed is controlled electronically by the engine management computer and is nor mally about 1250 rpm An uprated idle speed is required under certain operating conditions including the engine warm up phase during which time the raised idle helps to speed the time taken for the catalytic con verter to reach operating temperature as well as inhibiting engine stall Idle speed will return to normal automatically when the engine has warmed sufficiently 2000 03 E Lotus Service Notes Exige IGE F TRANSMISSION The Exige uses the same close ratio transmission as is fitted to the
509. preload will not allow the reservoir port to open Too little preload will allow free play and a rattle from the pedal Remove the locking grub screw 3 mm key in the end of the pedal trunnion apply Permabond A131 threadlock and refit loosley Screw the pushrod into or out of the trunnion until the pedal just contacts the pedal box flange upstop Apply 7 turn of preload to the pushrod and tighten the trunnion lock screw to 5 Nm Brake pedal Pedal to master cylinder pushrod Trunnion Trunnion grub screw 1170 Check the stop light switch adjustment With the pedal released check that the switch plunger is de pressed with about 1 mm of the white plunger visible If necessary twist the switch body 90 counterclockwise to release from the quickthread and reset its position to achieve specification Connect the brake pipes to the cylinder rear circuit to the rear port front circuits to the two front ports Fit the clutch fluid supply hose to the reservoir spigot 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 12 Lotus Service Notes Section JH JH 8 PEDAL BOX The extruded aluminium alloy pedal box is secured to the chassis scuttle via six horizontally disposed 6 screws three fixing each side of the box to a vertical bracket itself bonded and rivetted to the chassis An steel pivot s
510. pump 12 Camshatt timing 24 Rear cover New Patchlok bolt must be used when tensioner is refitted 14 DESCRIPTION AND OPERATION ENGINE ess FRONT TIMING BELT COMPONENTS 16 VVC ENGINES 20 12M3527A Screw upper front cover Upper front cover timing belt Camshaft gear bolt Washer Tensioner spring Pillar bolt Allen screw tensioner pulley Tensioner pulley and backplate Flanged head screw tensioner backplate Camshaft timing belt Front inlet camshaft timing gear ab These items are not fitted on production but are supplied with replacement timing belts They must be removed and discarded on completion of belt tensioning Screw timing belt rear cover Timing belt rear cover Exhaust camshaft front timing gear Crankshaft timing gear Seal lower front cover Lower front cover Screw lower front cover Crankshaft pulley Crankshaft pulley bolt and washer Seal upper front cover DESCRIPTION AND OPERATION 15 ENGINE REAR TIMING BELT COMPONENTS K16 VVC ENGINES 12M3528 1 Screw rear timing belt cover 7 Rear timing belt backplate 2 Rear timing belt cover 8 Bolt rear timing belt backplate 3 Rear timing belt 9 Rear inlet camshaft timing gear 4 Bolt M8 rear timing gear 10 Washer rear timing gear bolt 5 Washer rear timing gear bolt 11 Bolt M10 rear timing gear 6 Exhaust camshaft
511. r Distance collar 4th 5th gears Needle bearing 5th gear 5th gear Synchro ring 5th gear Synchro spring 5th gear Synchro hub 5th gear Synchro sleeve 5th gear Ball bearing input shaft Selective snap rings input shaft end thrust Belleville washer input shaft end thrust U in the 91 92 93 94 95 96 97 98 100 101 102 103 104 105 106 107 108 Oil guide plate Gearbox casing Reverse idler shaft bolt and washer Breather pipe Breather pipe bracket Oil seal differential Filler level plug Drain plug Access plug output shaft bearing circlip Reverse light switch Interlock assembly early gearboxes Gearshift holder Gearshift arm guide Shift shaft Roll pin 5th reverse gear selector Gear selector 5th reverse gears Selector fork 3rd 4th gears Selector fork 5th gear Selector shaft 5th reverse gears Selector fork 1st 2nd gears Selector shaft 1st 2nd gears Bearing roller Bearing ball Retainer plate output shaft bearing Retainer plate bolts Patchiok Clutch release shaft bush inner Clutch release shaft bush outer Interlock assembly later gearboxes Gear selector 5th reverse gears with reverse brake Spring reverse brake Lock plate reverse brake Taptite screws reverse brake DESCRIPTION AND OPERATION 3 MANUAL GEARBOX
512. r 132 5 kW 177 7 bhp 7 800 rpm Max torque 172 Nm 127 Ibf ft 6750 rpm Performance measures include a big valve cylinder head re profiled inlet and exhaust camshafts a new cast alloy 4 branch intake manifold with individual throttles large intake airbox and performance air filters large diameter 4 2 1 exhaust manifold and new muffler lightweight flywheel Lotus engine management system with maxiumum engine speed limited to 7 800 rpm Engine durability modifications include a forged crankshaft new forged connecting rods forged pistons with revised rings mechanical tappets 2000 03 de Exige Lotus Service Notes 22 do S S 2000 03 E Lotus Service Notes Exige onent locatio jagra Evaporative emission charcoal canister Fuel pump assembly Electronic Control Module ECM Engine Coolant Temperature ECT sensor brown Coolant temperature gauge sender blue Oxygen sensor Crankshaft position sensor Manifold Air Temperature MAT sensor Fuel injector 10 Engine management vehicle speed sensor 11 Fuel pressure regulator valve 12 Fuel rail 13 idle Air Control valve 14 Throttle Position TP sensor 15 Intake resonator valve 16 Ignition coil pack 17 Speedometer sensor 18 Fuel filter 19 Inertia Switch 20 Barometric pressure BARO sensor 21 Manifold Air Pressure MAP sensor 22 Resonator charging solenoid valve 23 Resonator locking
513. r or if a related component is replaced The specified gap of 0 25 to 1 25 mm may be adjusted if necessary by fitting shim washers between the sensor fixing tab and the mounting bracket Tighten the sensor fixing screw and bracket fixing screw to 9 3 Nm Ensure that the toothed ring does not become clogged with mud or accumulated dirt Shim washer i Pole wheel Sensor fixing Sensor Mounting bracket fixing Hub carrier DE 7 BARREL SHAPED ROAD SPRINGS In June 98 at approx VIN W 3580 the front and rear road springs were changed from parallel black painted to barrel shaped graphite coloured in order to provide increased spring stability and reduce the possibility of the spring fouling the damper body The barrel shaped springs use different abutment grooves in the damper body and revised rear damper chassis anchor brackets with repositioned 10mm higher damper pick up holes If an earlier car is to be updated with the barrel springs all four springs must be changed together with the following 1999 01 E Lotus Service Notes Section DE i Use the uppermost spring abutment groove on both front and rear damper bodies ii Replace each rear damper top mounting bracket with new bracketA111D0076F together with load spreading plate A111D0125F Discard the plain washers previously used on the fixing bolts New type damper top mount Damper bo roove Spreader plate Old type bracket US 1999 01
514. r removal of the radiator To Remove Radiator 1 Remove the front clamshell see sub section BN 4 2 Drain the coolant and disconnect the feed and return hoses from the radiator 3 Release the five fixings securing the water shield to the top rear edge of the radiator mounting panel and withdraw the shield 4 Release the tie wraps and unplug the rad fan harness connector 5 Release the eight fixings securing the radiator mounting panel to the crash structure three along the front edge three along the rear and one smaller self tapping screw at the lower edge of each side lower edge Lift away the panel complete with the radiator and fan Page 6 Lotus Service Notes Section KF Water shield Radiator inlet hose Radiator fixing screw Radiator Radiator Crash structure Radiator outlet hose 6 Release the fan motor from the radiator by removing the four nuts securing the fan shroud to the mount ing brackets rivetted to the radiator frame Withdraw the fan harness through the mounting panel grom met 7 Remove the four screws securing the radiator to the mounting panel 8 Refit the radiator in reverse order to removal and refill with coolant and bleed as detailed in sub section 7 amp Lotus Service Notes Section KF KF 5 RADIATOR FAN CONTROL The engine management ECM requires a coolant temperature input signal in order to increase fuel delivery and maintain driveabili
515. r 30 seconds Page 34 E Lotus Service Notes Section MN Location of Alarm Components Alarm controller on early cars may be fitted above passenger footwell Alarm harness Alarm harness to main harness Lucas 5AS module connector Main harness 4 way siren Touch key main connector socket Siren connector LH side of rear luggage compartment Engine management Cobra immobiliser ECM module Anti tamper cover Page 35 Lotus Service Notes Section MN MN 13 FUSES amp RELAYS Oct 97 onwards A new main fusebox and wiring harness was introduced in October 1997 at the following changepoint VIN W 1941 onwards plus 1920 1926 1937 1938 less 1965 2002 The passenger side of the front services compartment houses the main fusebox with provision for 22 Littel type fuses plus some spares A fuse extractor tool is clipped to the fusebox lid A separate relay block adjacent to the fusebox houses four relays protected by a clip on cover RHD shown Ku DORN JOAN Fuses Slot Rating Circuit Slot Rating Circuit 1 3A Rear fog lamp 12 25 Cooling fan 1 2 2A Alarm ignition 13 25 Cooling fan 2 air only 3 20 Interior fan 14 20 Audio 4 15A Wiper motor 15 20 Cigar lighter 5 3A Reverse lamp 16 5 Sidelamp LH 6 7 5A Direction ind 17 Sidelamp RH 7 10A Ignition services 18 10 clutch air con only 8 7 5 Stop lamps amp 19
516. r access to the instrument pack orumn upper shroud mounting brackets it is necessary first to re move the column shroud Release the four screws securing the shroud upper section turning the steering Wheel as necessary to permit access Puli out the grommet from around the ignition switch and remove the three screws securing the lower shroud to the column If necessary disconnect or remove the trip panel lights control button and immobiliser socket from the lower shroud Instrument cowl Shroud mounting bracket Instrument pack Instrument amp cowl mounting bracket Column lower shroud The two fixings for the instrument pack mount ing brackets may now be released and the single harness connector unplugged allowing the instru ment pack complete with cowl to be withdrawn If necessary release the four fixing nuts to separate the mounting brackets and cowl from the instrument pack Page 23 e Lotus Service Notes Section To Dismantle Dash Panels 1 Release the four screws securing the steering column shroud upper section turning the steering wheel as necessary to permit access 2 Pull out the grommet from around the ignition switch and remove the three screws securing the lower shroud to the column 3 Squeeze the dash panel plastic moulding vertically and pull out from the centre extrusion 4 Release the three screws securing the dash top and centre extrusions
517. r bolt turning clockwise to increase tension When tension is correct tighten the pulley nut to 25 Nm and recheck tension Compressor Removal 1 Recover the refrigerant using equipment connected to the service ports at the right hand front of the engine bay 2 Remove the RH rear wheel and engine bay undertray if fitted Access to the compressor mounting bolts and pipe connections will be improved if the engine mounting tie bar at the back of the engine is released and the engine is moved backwards slightly 3 Release the pipe support clamp adjacent to the service ports and 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 cable Compressor a c pipe mounting bracket steady bracket Discharge port Belt tensioner clamp nut Compressor fixing bolts Suction port 5 Slacken the belt tensioner pulley nut and release belt tension Release the three M10 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 2000 04 EM Eb Lotus Service Notes Section PH il i justment Pri m efitmen Refitting Existing Compressor i existing compressor is to be refitted after normal refrigerant recovery has been performed a quan tity of oil equivalent to that
518. r compartment lids iv Connect the power harness crockodile clips to the battery in the front compartment Plug the adaptor harness into the 16 terminal diagnostic link connector DLC vi Select MEMS on the adaptor harness switch vii Press F2 Whenever the ignition is switched on or the engine is running the ECM monitors the readings of all the sensor inputs and compares them with pre programmed tolerance bands If any readings should fall outside of these tolerances the fault will be recorded in memory and a substitute default value used to enable the engine to continue to run at a reduced performance level If the fault is intermittent and is no longer present when the ignition is next turned on the ECM will reinstate the sensor input but will record the fault in memory Dependent on the nature of the fault this may or may not have been noticed by the driver At each maintenance service the Lotus Check tool should be connected and the Pre Test selected from the main menu to check whether any faults have been detected since the last Pre Test This test takes only a few minutes during which the scanner display will ask a series of questions and issue instructions to guide the operator through the test which is self explanatory with the following special notes s fuel rail temperature sensor fitted answer NO How many cooling fans are fitted answer 1 References to a current camp are not applicable in this
519. racket tighten bolts to 45 and cylinder head fitted Nm 2 OVERHAUL ENGINE Hesse 9 Ensure inserts are fitted in timing belt lower cover 10 Fit timing belt lower cover ensuring correct position of seals tighten screws to 10 Nm 12M3757 11 Fit crankshaft pulley 10 crankshaft timing gear ensuring that indent on pulley locates over gear lug arrowed 12 Fit crankshaft pulley bolt and washer tighten to 205 Nm 13 Remove flywheel locking tool 18G 1571 12M3758 14 Slacken tensioner backplate screw and tension timing belt by applying finger pressure to tensioner backplate 15 16 17 18 19 20 With tensioner pulley against timing belt and backplate held in position tighten backplate screw to 10 Nm Rotate crankshaft clockwise 2 complete revolutions and align camshaft gear timing mark with top face of cylinder head CAUTION Do not use camshaft gear gear retaining bolt or timing belt to rotate crankshaft Slacken tensioner backplate screw and check that belt is being tensioned by the tensioner spring Tighten tensioner backplate screw to 10 Nm and tensioner pulley Allen screw to 45 Nm Ensure inserts are fitted in timing belt upper front cover Fit timing belt upper front cover ensuring correct position of seals tighten screws and bolt to 5 Nm OVERHAUL 3 CAMSHAFT TIMING BELT K16 ENGINES Camshaft timing manual tensioner remove
520. racteristic 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 rubber grease to ease fitment and assemble as follows Top wishbone insert a single 30mm long bush into each pivot eye from the outside end front of front eye and rear of rear eye Front pivot Rear pivot Plastic interleaf FRONT Bush inserted Bush inserted from front from rear TE 1998 02 Lotus Service Notes Section DE 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 Front pivot Rear pivot daf FRONT Pivot mounting Plastic Rear bracket interleaf subframe my m 22224222222 F ra Weldnut Short pivot Long pivot bush Toe control bushes inserted from front link ball joint 919 12 The road spring may be removed from the damper using a suitable spring compressor to allow the spring collar retaining circlip to be released from its damper body groove Note that the springs were changed in June 98 from parallel black to barrel shaped graphite for improved spring stability For parallel springs the middle spring abutment circlip groove is used whereas the barrel shaped springs use the top groove lowest ride height 13 Re assemble the suspension in reverse order to disassembly with the following notes For as
521. rail At the front end between the suspension wishbone pivots and at the extreme rear end of each rail 2 Measurethe 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 dimen sion 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 Front wishbone Rear wishbone Page 4 Lotus Service Notes Section AF AE3 REA BFRAME amp LO ON The rear ends of the chassis siderails are linked by a fabricated sheet steel subframe which provides rear suspension mountings and an anchor point for the engine rear steady bar At each side an extruded box section longeron is rivetted and bonded to the top surface of the subframe and extends rearwards to provide rear body support On cars built prior to September 98 an aluminium sheet floor is rivetted between the longerons with a boot front bulkhead bolted to the front edge of the floor On later cars the floor panel and bulkhead are replaced by a boot box moulded integrally with the rear clamshell Io remove rear subframe assy 1 Remove the rear clamshell s
522. rail to bearing ladder tighten nuts to 9 Nm CAUTION A new oil rail together with a plastic suction pipe must be fitted if a thread for cylinder head bolts is damaged Thread inserts Helicoil are not acceptable 15 Fit cylinder retainer clamps 18G 1736 screw bolts into oil rail and tighten sufficiently to retain clamps 16 Lubricate a new O ring with engine oil and fit to oil suction pipe 17 Fit oil suction pipe fit screws and tighten to 12 Nm 0 CAUTION Screws used must be M6 20 88 OVERHAUL Pressed steel sump 18 Clean inside and joint face of sump Check condition of gasket renew if damaged or showing signs of deterioration 19 Fit gasket to sump ensure its 7 pegs are fully located 20 Fit sump to bearing ladder fit 11 new Patchlok bolts and using sequence shown tighten to 5 Nm CAUTION Early engines M6 bolts Later engines 8 bolts 21 Fit anti beaming bracket support where fitted fit and tighten 3 new M6 or M8 x 35 Patchlok bolts at positions 4 8 and 12 to 5 Nm 22 Progressively tighten sump bolts in sequence shown to M6 MB bolts 10 Nm 23 Fit anti beaming bracket where fitted tighten boit to 45 Nm ENGINE eese Alloy sump 24 Clean sealing surface on sump flange using suitable solvent y WE WP 1291782 25 Apply a 2 mm wide x 0 25 mm thick continuous bead of sealant Part Number GUG 705963GM to sump flange as shown then spread to an even film us
523. rased GO Te 12 1788 5 Apply 2 0 mm thick continuous bead of sealant from kit Part Number GGC 102 around shoulder of cylinder liner CAUTION Do not use any other type of N sealant 6 Keeping cylinder liner square to cylinder block push liner fully down until shoulder of liner seats against cylinder block Do not drop liners into position CAUTION If original cylinder liners are to be refitted align reference marks made during dismantling before liner is pushed fully down 7 Fit cylinder liner retainer clamps 18G 1736 8 Fit pistons 96 OVERHAUL 1 Pistons and connecting rods refit 1 2 Using assistance support base of cylinder block on 2 wooden blocks Ensure that cylinder liner retainer clamps 18G 1736 are fitted and that feet of clamps do not protrude over cylinder liner bores Lubricate cylinder bores pistons and rings with engine oil ensure ring gaps are correctly spaced Fit selected bearing shells into big end bearing caps and connecting rods 186 55 BRM 3504 5 Fit ring clamp 18G 55 to each piston in tum and with FRONT mark on piston to engine front push piston into bore until flush with top face of cylinder liner Remove ring clamp CAUTION If original pistons are to be fitted ensure that each piston is inserted in its correct cylinder liner Do not push pistons below top face of cylinder liner until b
524. re angle Unladen weight std total front rear 111S total front rear Max weight std total front rear 1118 total front rear Trailer towing CAPACITIES Engine oil dry refill inc filter High low dipstick mark difference Transmission oil dry refill Fuel tank Coolant Refrigerant R134a TYRES Normal Use Standard Fitment Type Size front rear std 1115 amp std option Pressure cold front 205 225 3726 146 7 3734 147 0 1701 67 0 1703 67 0 1850 72 8 1148 mm 45 2 2300 90 6 1440 56 7 1458 57 4 1470 57 9 160 6 3 746 29 4 680 26 8 688 27 1 12 4 28 755 kg 166416 gt 303 kg 668 Ib gt 452 kg 996 Ib gt inc full fuel tank 770 kg 1698 Ib gt 303 kg 668 gt 467 kg 1030 Ib gt 974 kg 2147 Ib 386 kg 851 b 588 kg 1296 Ib inc 992 kg 2187 Ib occupants 376 kg 829 Ib amp luggage 616 kg 1358 Not permissible 5 0 litre 8 8 imp pt 4 5 litre 7 9 imp pt 1 0 litre 1 8 imp pt 2 4 litre 4 2 imp pt 2 1 litre 3 7 imp pt 36 4 litre 8 0 imp gall 8 0 litre 14 1 imp pt 0 85 kg 1 87 Ib Pirelli P Zero 185 55 R15 81V 205 50 ZR16 87W 225 45 ZR16 1 6 bar 23 Ib in 1 7 bar 24 5 Ib in 1 9 bar 27 5 Ib
525. re different front and rear so that interchanging of wheels and tyres between axles is not permissible Note that the tyre tread pattern is asymmetric with the tyre sidewalls marked Inner and Outer check that replacement tyres are correctly fitted Part of the tread pattern is also directional in appearance but the direction of rotation has no bearing on the tyre performance 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 be readily 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 an
526. re of the cabin floor beneath the fuel tank bay and under the engine to connect with the transmission selector shaft at the bottom rear of the power unit A vertical extension to the gearchange lever below the pivot ball connects via a ball joint to the shift cable Fore aft movement of the lever is thus transmitted directly to the cable the rear end of which is connected directly to the transmission selector shaft via a short leg Crossgate movement of the gear lever is transmitted to a second cable via a short horizontal leg protrud ing from the left side of the gear lever pivot ball Vertical movement of this leg is translated into a fore aft motion by a foreward mounted bellcrank lever the other end of which connects with the crossgate cable The rear end of this cable links via another bellcrank lever and a ball jointed link to a lever on the transmission selector shaft to which is imparted a rotational movement Page 2 E Lotus Service Notes Section FH Gear lever ros Gear lever crossgate bellcrank Crossgate movement T Fore aft movement Gear select Transmission cable crossgate Transmission bellcrank selector Cable front abutments Cable rear Crossgate abutment cable Selector shaft lever Gearchange Cable Adjustment Both gearchange cables crossgate and select are of fixed length Fore aft adjustment is provided via slotted fixing holes in the transmission end abutment bracket with crossgage adju
527. rear 541 kg amp luggage Trailer towing Not permissible SS a TT EIE GE ee Page 2 The bonded aluminium alloy chassis structure is derived from the standard Elise chassis but has no door hinge mountings and the sill top edge support flanges are replaced by channel strips to mount the cockpit side screens The galvanised steel rear subframe is fitted with additional weldnuts and has been commonised for the standard Elise No chassis rear longerons are used but a thick machined alloy plate is bolted to each rear corner of the subframe to support the carbon fibre rear aerofoil The special roll over bar comprises individual hoops for driver and passenger interlinked to form a crossbraced structure fabricated from oval section steel tubing with back stays anchoring to the rear aerofoil mounting plates The composite front crash structure is revised to accommodate the new body and is supplemented by a new aluminium front undertray which incorporates longitudinal rivetted box sections Note that as on the standard Elise the bolted on closing panel below the fuel tank bay is a structural panel and contributes to the rigidity of the chassis On no account should the car be driven with this panel removed Abbreviated door hinge crossmember Side screen channel section 1806 Fuel tank closing panel Page 3 i Lotus Service Notes 340R 340R B BODY The non structural composite body structure is minimalist and functional wi
528. 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 and measure the remaining oil from the compressor by removing the drain plug and rotating the clutch plate Add 170 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 170 cm i If normal refrigerant recovery has been performed the required oil level in the new compressor must be calculated and the appropriate quantity drained off Drain and measure the oil quantity in the OLD compressor by removing the drain plug and rotating the clutch plate Quantity X cm Calculate the quantity of oil Q cm to be drained from the new compressor using the formula Q cm 170 X 20 Remove the drain plug from the NEW compressor and drain this quantity of oil before refitting and tightening the plug ii 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 the 170 cm of oil contained in the new compressor is to be retained Co
529. remain lit after releasing the parking brake or light any time whilst driving stop the car immediately as the level of brake fluid in the master cylinder reservoir may have fallen to a dangerously low level 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 spongey operation and extended pedal travel The split brake circuit should ensure that emergency braking will remain but the car should not be driven until the fault has been rectified Heated Windscreen Tell Tale yellow This tell tale indicates when the windscreen heating element is energised Refer to the text below describ ing the switch function for the operating conditions Rear Foglamp Tell Tale amber This amber tell tale indicates when the rear fog lamp is active The rear fog lamp operates only in conjunction with the ignition and headlamps and defaults off if either of these circuits is interrupted Turn Tell Tale green 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 Main Beam Tell Tale blue This lamp glows blue whenever the headlamp main beams are operating Shift Light red The shift light provides a visual aid to identifyin
530. retaining pin and the anti rattle spring plate Withdraw the pads from the caliper Measure the lining thickness and renew the axle set of pads if any lining is below 2 5 mm Pad securing pin Anti rattle spring plate 1998 03 Lotus Service Notes Section JH 2 Before replacing the pads inspect the caliper for any signs of fluid leakage from a piston seal or joint and replace the caliper if any such signs are evident Clean the pad recess in the caliper taking suitable precau tions to protect from dust inhalation 3 frefitting the existing brake pads refit each pad the same position as originally fitted 4 If fitting new pads the pistons must be pushed back into the caliper 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 caliper and insert the upper pad retaining pin from the outboard side Secure with the split pin 6 Fittheanti 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 caliper 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 positio
531. ring from flying off as the pin is withdrawn Retaining f pin snap ring OY e AD lt 3 Remove the anti rattle spring and with draw both brake pads from the caliper Measure the thickness of the lining ma v terial and renew the axle set of pads if any are below 2 5 mm Anti rattle spring 1998 N3 Lotus Service Notes Section JH 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 caliper should be replaced as Brembo do not recommend that this caliper be dismantled If refitting the existing brake pads refit each pad in the same position as originally fitted Before fitting new rear pads the caliper piston must be screwed back into the caliper down the parking brake actuation mechanism This operation requires the use of special tool T000T1242 andthe removal of the brake disc Remove the single socket head screw retaining the brake disc and remove the disc Fit special tool 100011242 into the holes in the caliper 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 Slide the brake pads into the caliper Position the pad anti rattle spring in the caliper aperture with t h e spring ends located in the recesses provided Ensure that the spring is f
532. rly apply to the whole of the bonding surface on the windscreen frame and to the wind A screen bottom laminated edge Allow to dry V for a minimum of 5 minutes If the screen V 10 mm is not fitted within 48 hours the primer should be re applied 60 10 Cut the nozzle of the Betaseal cartridge to the dimensions shown to produce a trian gular section bead Holding the cartridge vertically extrude a bead of adhesive around the screen using the edge of the rubber finisher strip as a guide along the top and sides and following the centreline of the primer band along the lower section Page 26 11 Cut three 4 mm spacer blocks from the material supplied and position in the inside edge the adhesive bead running along the bottom of the glass These spacers are used to control the fitted height of the glass and the wiper arm clearance 12 Using suction handles carefully lower the windscreen onto the frame with the edge finisher firmly butted against the top and sides of the frame recess Press the bottom of the screen until contact is felt with the spacer blocks and press around the top and sides of the glass to ensure a similar compression of the adhesive bead 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 all
533. rod from the interior release handle and unhook from the latch mechanism Unclip and dis connect the short link between the relay lever and the latch mechanism Remove the three M6 screws securing the latch mechanism to the door and withdraw the latch Control rod to latch Rod to exter or button Plain amp spring washers Pivot bush Relay lever shaft V ul M e Lotus Service Notes Section DN Lotus Service Notes Section BN To remove the door beam extension bracket 1 Remove the trim panel around the interior release handle Remove the two screws in the front edge of the finisher and unhook the finisher from the handle and door shell 2 Release the three screws securing the interior release handle and unclip the control rod from the mecha nism 3 Remove the door trim panel Unclip the cap from the window winder handle release the retaining screw and withdraw the handle Release the seven fixing screws and remove the door trim panel and plastic membrane 4 Release the three M6 nuts securing the door glass to the lift channel and separate the glass from the channel Do not attempt to withdraw the glass from the door without first removing the door glass inner waist seal or damage to one or both waist seals will result 5 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 l
534. ront and rear inlet camshafts are retained in camshaft carrier and VVC assemblies carefully release camshaft carner from cylinder head NOTE Dowel located LS 23 Lift camshaft carrier together with front and rear inlet camshafts off cylinder head CAUTION Ensure that exhaust camshaft AN is retained in cylinder head as camshaft carrier is removed 24 Ensuring that front and rear inlet camshafts are retained in camshaft carrier invert carrier 40 OVERHAUL 12M3526A 25 Slacken but do not remove 2 bolts securing each VVC housing to camshatt carrier NOTE Bolts shoutd only be slackened sufficiently to enable timing plates 18G 1770 1 and 18G 1770 2 to be fitted ENGINE 1801770 18G1770 2 18G1770 186 1770 1 27 les 30 4 29 12 3490 26 Fit timing plates 186 1770 1 to front and 186 1770 2 to rear VVC assemblies 27 Assemble clamps 18G 1770 to front and rear inlet camshafts and VVC assemblies fit camshaft gear bolts and washers to retain clamps 28 Suitably identify each VVC assembly to its fitted position Do not attempt to interchange front and rear assemblies 29 Remove and discard 2 bolts securing each VVC housing to camshaft carrier 30 Remove front and rear camshafts together with VVC assemblies CAUTION Do not remove clamps 18G 1770 31 Remove control shaft from camshaft carrier 12 3521 32 Remove exhaust camshaft from cylinder head
535. ror 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 Replacement of mirror assembly The mirror assembly locates in the plas tic injection moulded plinth via two spigots and is retained by a single screw tapping into the lower spigot To remove a mirror assem bly 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 bot tom leg Access to the recessed socket head upper screw is readily available but access to the lower hex head screws is difficult with a fully assembled door It is possible to ac cess the screws using a suitable flexi drive via the interior door handle aperture if the handle is removed but for easier access it is necessary to remove the door assembly from the beam see sub section BN 8 When refitting ensure that foam gaskets are used between each leg of the plinth and the door shell Socket head screw Fixing Mirror assembly screw Foam gaskets
536. rottle body and release the tank breather pipe from its clips along the rear side of the engine 14 Disconnect the engine harness from the relay module ECM and associated connector blocks Discon nect the main battery cable from the starter solenoid and the cable from the solenoid to the positive post 15 Release the MAP sensor hose from the fuel trap at the right hand end of the intake plenum 16 Support the power unit before removing the LH engine mounting brackets from the transmission housing Release the RH engine steady arm and release the mounting bracket from the RH end of the engine 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 A100R6001F on the end of the inboard joint spigot shaft 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 shaft assembly into the transmission with the lubricated circlip fitted on the end of the spigot shaft Press the C V joint into the differential gear splines until a click indicates that the circlip has engaged in its location Pull on the body of the joint to check securit
537. rough the side of the crash structure and fit the grommets into the holes Connect the hoses to the oil cooler and secure the LH hose the the centre rib on the crash structure using a P clip Fit the front topshell and secure the two hoses around the top of the wheelarch liner using P clips before fitting the liner Disable the ignition and crank the engine to fill the oil cooler and pipes before starting the engine Check the hose connections for leaks before fitting the new front undertray with the swaged aperture pointing downwards Page 25 S Lotus Service Notes Section XA XA 12 BATTERY ISOLATOR SWITCH KITS This dual pole flick switch is mounted in the cabin and operates the ignition circuit directly and via a relay in the battery compartment all other battery services An alternator dump resistor is incorporated to protect the alternator from damage In addition external operation of the switch is provided for by a Bowden cable link from a pull handle located in the topshell near the windscreen base Contents of Kit Battery Isolator Switch Kit prior intro of revised harness A111M0128S 1 Battery Isolator Switch Kit from intro of revised harness A111M0129S comprising Switch Box Assembly prior revised harness A111M0126S 1 Switch Box Assembly revised harness A111M0125S 1 Master Switching Relay A111M6087S 1 Bowden Cable A111M6088S 1 Battery Positive Link Cable A111M0109S 1 Miscellaneous Parts
538. rrier ensuring reference marks are aligned Fit 10 bolts and tighten progressively to 110 Nm Differential Bearing Pre load Check and Adjust gt 26 Position original selective circlip in gear case Position differential assembly in differential housing Fit gear case fit and tighten bolts to 45 Nm Lightly drive differential assembly into gear case to seat circlip Lightly drive differential into differential housing to settle bearing 37M0172 Using feeler gauges measure and record clearance between circlip and bearing outer face Correct clearance 0 15 mm maximum OVERHAUL 7 If clearance is not as specified select the appropriate circlip from the range available NOTE Circlips are available from 2 50 ta 3 00 mm thick in increments of 0 10 mm Remove original circlip through oil seal aperture using tool 18G 1392 Fit selected circlip using tool 18G 1392 Re check bearing pre load using above procedure Remove differential assembly retain selected circlip MANUAL GEARBOX GEARBOX ASSEMBLING 1 Lightly lubricate all components with gearbox oil 5 Fit a new input shaft oil seal in differential housing using tools 18G 1354 and 18G 1354 4 A 37M0174B 2 Using a suitable piece of tubing fit a new selector shaft oil seal 3 Fit output shaft oil guide plate in differential housing 5 37M1294 6 Fit input shaft beari
539. rrier sealed and bolted to the cylinder head Positive location is by means of a flange which also controls camshaft end float 16 engine The cross flow cylinder head is based on a four valve central spark plug combustion chamber with the inlet ports designed to induce swirl and control the speed of the induction charge This serves to improve combustion and hence fuel economy performance and exhaust emissions The twin overhead camshafts operate the valves via hydraulic tappets one camshaft operates the exhaust valves whilst the other operates the inlet valves The camshafts are driven from the crankshaft by a timing belt belt tension being maintained by either a spring loaded manually adjusted tensioner or on later engines by an automatic tensioner The camshafts are retained by the camshaft carrier which is line bored with the cylinder head Later engines are fitted with a plug top coil ignition system in which the conventional distributor is replaced by a camshaft sensor located in the camshaft carrier adjacent to the exhaust camshaft Camshafts fitted to some early engines and all engines with plug top coil ignition have an integral reluctor ring which provides an input to the camshaft sensor Twin coils are fitted on top of the camshaft cover each coil supplying ht voltage to one pair of spark plugs Variable valve control VVC This system is fitted to some K16 engines VVC is designed to provide variation in the valve
540. rrier to be leant outwards and provide room for the driveshaft to be withdrawn from the transmission and hub remove the bolt securing the toe link to the hub carrier and remove the two bolts securing the top ball joint plinth to the hub carrier taking note of the shim pack fitted between plinth and carrier 6 The inboard C V joint is retained in the transmission by a rounded section circlip and may be removed using a special wedge tool TO00T1276 or by applying a shock pull to the 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 This action will cause the joint to become disassembled and may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive axial force is used Apply pressure only to the or outer body of the joint Withdraw the inboard C V joint from the transmission taking great care not to damage the output seal and fit blanking plug TO00T1385 into the transmission to limit the amount of transmission oil loss 7 Withdraw the driveshaft from the hub using a puller if necessary and remove the driveshaft assembly from the car 8 Before re fitting a driveshaft first renew the round section circlip A100R6001F on the end of the inboard joint spigot shaft and lubricate the c
541. rvice 2 3 hr B Service 2 7 hr C Service 6 2 hr Add 0 5 hr to all if undershield fitted r service table sn_og_t3 eps 2d 1998 03 Lotus Service Notes Section OG PRE DELIVERY INSPECTION ESPRIT V8 amp ELISE LSL345 Model Colour VIN SCC Checkengme amp wansmission Check engine amp transmission for oil leaks Check security of battery terminals Check operation of all exterior amp interior lamps Check operation of headlamp pods Check headlamp alignment x t service table sn_pdt eps X Check torque of wheel bolts X Check operation of horn s amp hazard switch X X X 1002 N3 Page 7 Lotus Service Notes Section OG Esprit Front Spoiler Li The two part front spoiler lip is supplied in the 4 luggage compartment complete with fixings The lip is fitted between the oil cooler undershields ST and the spoiler Remove the 4 fixings from each undershield and insert the spoiler lip Refit the li M6 fixings and secure the remainder of each lip T with the 4 Scrivets supplied using the pre drilled holes in the spoiler Oil cooler undershield Esprit Elise Front Licence Plate When fitting the front licence plate in or der to ensure that airflow to the radiator is Licence not unduly restricted the bottom edge of plate the plate should be aligned with the plinth on both Esprit and Elise models Mounting p
542. rvice Notes Section KF REI GENERAL DESCRIPTION The engine cooling system comprises an engine driven water pump a front mounted radiator with elec tric cooling fan and associated pipework and controls The centrifugal water pump is mounted on the front face of the cylinder block and is driven by the camshaft toothed 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 elbow at the left hand rear of the head From the outlet elbow there are three routes through which water may flow Radiator circuit The larger of the two spouts on the outiet elbow is connected via an alloy pipe running through the chassis right hand side rail to the front mounted radiator Water returns from the radiator via a pipe in the chassis left hand side rail to the engine bay One of a pair of steel tube water rails then directs this water around the back and the right hand side of the engine to a plastic bodied thermostat housing fixed to the back of the water pump Heater circuit A take off for the heater is provided in the radiator feed circuit at the right hand front of the engine bay from where it is routed through an alloy pipe fixed to the outside face of the RH chassis side rail to the heater matrix mounted between the front chassis rails Water returns from the heater via a pipe routed outside the LH chassis side rail and a second steel
543. s NOTE This will enable camshafts to be rotated in order to enable bolts 3 and 4 to be tightened OVERHAUL 71 ENGINE 9 Tighten alt 10 cylinder head bolts progressively in sequence shown to 20 Nm Use a telt tip pen and mark position of radial mark on each bolt head Tighten all bolts in sequence shown through 180 Tighten all bolts in sequence shown through another 180 and align mark CAUTION If any bolt is overtightened back off 90 and re align 10 Upon completion of tightening sequence position camshafts with inlet pin at 4 o clock and exhaust pin at 8 o clock remove timing gears CAUTION Ensure camshafts do not rotate when gears are removed 11 Fit camshaft cover and timing gears 12 Fit new spark plugs tighten to 25 Nm If fitted 13 Connect multipiugs to coils position coils to numbers 1 and 3 spark plugs fit bolts and tighten to 8 Nm 14 Secure multiplug hamess in clips 15 Connect HT leads to numbers 2 and 4 spark plugs secure leads in clips 16 Position multiplug bracket to camshaft carrier fit bolts and tighten to 15 Nm All engines 17 Lubricate new O ring with engine oil and fit to camshaft sensor 18 Fit camshaft sensor fit bolt and tighten to 5 Nm secure hamess in clip 19 Fit timing belt tensioner pillar bolt and tighten to 25 Nm NOTE Do not fit timing belt tensioner until AS camshaft timing belt is fitted Cylinder head K16 VVC engines refit C
544. s The main fusebox is located in the front serv ices compartment on the passenger side and is protected by a clear plastic cover 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 tid A relay block adjacent to the fusebox houses four relays protected by a clip on cover EE Fuses Slot Rating Circuit Slot Rating Circuit 1 3A Rear fog lamp 12 25 Cooling fan 2 2A Alarm ignition 13 3 20A Interior fan 14 20 Audio 4 15A Wiper motor 15 20A Cigar lighter 5 3A Reverse lamp 16 5A Sidelamp LH 6 7 5A Direction ind 17 5 Sidelamp RH 7 10A Ignition services 18 8 7 5A Stop lamps amp 19 battery services 20 20 Fast fan speed relay 9 10A Hazard lamps 21 10 7 5 Horn 22 11 10A Alarm amp Int lamp Relays A Horn Dip beam B Cooling fan D Main beam Two Maxi fuses are located in the front services compartment beneath the wiper motor protective cover Slot Rating Circuit A 50A Lighting B 50A Ign switch Engine management and security system related fuses relays and modules are contained within the electronics box on the cabin rear bulkhead A pull off panel is provided for ready access 2000 03 k roni X Fuel pump injectors Engine Alarm microwave management Engine management OBD sensor controlfer Engine man
545. s this will be acknowledged by one hazard lamps flash and the alarm tell tale going out Page 32 Lotus Service Notes Section MN Emergency Disarming In the event of lost or failed transmitter keys an electronic touch key may be used to mobilise the engine Enter the vehicle causing the alarm to be triggered if it is armed and with the ignition OFF insert the touch key into the receptacle on the right hand side of the steering column shroud This will disarm the alarm and mobilise the engine Note that if this operation is performed with the ignition ON the transmitter key codes will be wiped and must be reprogrammed see below Passive immobilisation will still function after the appropriate delay see above requiring another inser tion of the touch key with ignition OFF to overcome New Transmitter Programming If a transmitter key is lost or damaged a new uncoded key may be ordered and then programmed to a particular car using the following procedure 1 With the alarm system disarmed and mobilised switch on the ignition Note that if the transmitter key codes have been wiped the alarm must be disarmed using the touch key see above 2 Inserta touch key into the receptacle on the steering column shroud The alarm tell tale will light steady 3 Press simultaneously both buttons on the new transmitter key for about ten seconds until the tell tale in the key stops flashing and goes out When the buttons are released the
546. s Section 16 340R 340 PS TONNE RHD A340X6007S LHD A340X6014 LSL389 The purpose of the 340 ps tonne kit is to optimise the performance potential for use on closed race tracks Amajor part of the package involves the removal of components to save weight with the full procedure below resulting in a dry weight of 571 kg With a power output of 195 ps a power weight ratio of 340 ps tonne is achieved The RHD kit includes an oil cooler fitting kit which is factory fitted on LHD cars Kit Contents Engine 190 bhp ECM surcharge on old unit 101 Inlet cam pulley Breather hose kit 82 C thermostat Track exhaust muffler stainless steel RHD kits only Oil cooler kit Grommets for airbox backplate and oil catch tank Blanks for inlet manifold IAC ports Clutch Uprated higher clamp clutch cover Uprated material friction plate Standard release bearing Chassis Road spring set Pagid Motorsport brake pad set Castrol racing brake fluid Goodridge braided brake hose Body Rear diffuser panel and brackets Carbon fibre headlamp blanks Polycarbonate windscreen Electrical Lightweight race battery Rear racelight conversion kit Immobiliser bridging link Sidelight switch connector bridging link Hazard switch aperture grommet Column switch aperture blanks Alloy cover for bulkhead electrics box Miscellaneous Carbon fibre seat Removable 305mm steering wheel kit Elise gear lever surround Driver only roll over bar RHD or
547. s bonded to the front face of the chassis and is braced by a flat 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 Page 10 Lotus Notes Section EN Lotus Service Notes Section BM To remove the structure Remove the front clamshell see sub section 4 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 KF Remove the driving lamps if fitted from the crash structure along with the towing strut horn 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 u
548. s described within this manual Page 48 Section XA Lotus Service Notes 2 ejqeo jo uogisod 3uauinagsuj jo apisiepup yojims K16 04 404 ejou ejqe2 10 JO S uognq ysnd 10 380d y uo jejuozuou poJ e4ju s 49 2000 02 E Lotus Service Notes Section XA 24 340R COMPETITION ROLL OVER BAR RHD 40 0036 LHD A340A0037 LSL401 The driver only competition roll over bar is available for RHD or LHD cars and is RAC approved for competition use in the U K provided tha assenger seat is not fitted in the vehicle The roll bar is a direct replacement for the standard 340R double hoop bar and includes an anchorage bar for the standard fit compe tition seat belt harness shoulder straps Fitting Instruction 1 Remove the topshell refer to Elise Service Notes section 340R B and the double hoop roll over bar 2 Fitment of the new bar requires a clearance slot to be cut in the engine lid and body aperture gutter template LSL401 for the engine lid slot is provided below to allow an initial fit to be made with initial dimensions for the body aperture measureable from this The spoiler mounting plate will also require a small clearance groove to be made to allow the backstay to be connected The body on each car will require individua
549. s must be fitted dry Do not use tool 18G 1769 for fitting seals as they will not be positioned correctly within recess Camshaft carrier and oil seals All K16 Non VVC engines refit 1 Ensure 2 locating dowels are fitted in camshaft carrier Ke 157 deier a MI 1223523 2 2 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on cylinder head as shown then spread to an even film using a roller CAUTION Ensure sealant is kept clear of tappet oil feed holes and lubrication grooves in carrier and that assembly is completed within 20 minutes 3 Lubricate camshaft cams and journals with engine oil Yes e Te PEER I PEt 2 23 19 6 U 1 8RM 0056 4 Fit camshaft carrier fit and progressively tighten bolts in sequence shown to 10 Nm 62 OVERHAUL 18G 1769A i NOTE Camshaft front oil seai illustrated 5 Position oil seal protector 18G 1749 over end of camshaft 6 Fit new camshaft oil seals using tool 18G 1769A NOTE Front oil seals are coloured A BLACK rear oil seals are coloured RED CAUTION Oil seals must be fitted dry Do not use tool 18G 1769 for fitting seals as they will not be positioned correctly within recess 7 Fit blanking plate s fit and tighten bolts to Inlet camshaft plate Plug top coil ignition engines only 6 Nm Exhaust camshaft plate All engines 25 Nm Camshaft carrier and camshafts K16 VVC engines re
550. s 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 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 Ge 2000 03 EO ELISE MODEL HISTORY Model Introduction June 96 VIN T 0017 onwards 1997 Model Year November 96 VIN V 240 onwards No specification change Uprated Starter Motor February 97 VIN V 685 Starter motor uprated from 1 0 kW to 1 4 kW and engine management fuse relocated from rear to front services compartment Commonisation of a c type chassis September 97 VIN V 1685 approx Plus 1672 1673 1677 1682 Less 1694 1708 Shape of chassis rear side of fuel tank crossmember changed to accommodate a c compressor Low level engine coolant outlet pipe Re circ ventililation holes in chassis toe board 1998 Model Year October 97 VIN W 1814 onwards No s
551. s side rails Air to windscreen and or face level Swivel vents To driver s footwell Distribution flap To passenger footwell Convoluted ducting Heater matrix Temperature control flap v Med inlet collector Blower fan Chassis Crash structure duct G 25 f Ambient air from radiator air intake Page 2 E Lotus Service Notes Section PF Heater Circuit Heater feed pipe Cylinder head outlet pipe Thermostat housing Heater return radiator by pass rail Footwell vent adaptor Matrix housing Distribution flap rubber strap housing Matrix air feed adaptor Heater matrix Convoluted ducting Air inlet collector Blower fan unit Temperature flap amp matrix housing Page 3 Lotus Service Notes Section PF A cable operated air blend temperature control flap operates between a heater matrix outlet doorway and a matrix by pass port and controls the proportion of hot and cold air supplied to the blower fan unit The blower fan is mounted alongside the heater and centrifuges air admitted into the inside of the drum fan into a convoluted air duct leading to the diverter flap assembly mounted on the scuttle The diverter flap has a vertical pivot and is cable operated to control the proportion of air flowing to the footwells and fascia vents via a divided aperture in the scuttle footwell vents and a duct moulded into the underside of the fasci
552. secured using the Gurit Essex products 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 Pneu Nife 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 Chicago Pneumatic Utica New York 13501 USA Catalogue no CP838 Pneu Nife Recommended air pressure 60 90 PSIG 4 0 6 2 bar air inlet 1 4 NPTF 3 8 min hose size Page 9 Lotus Service Notes Section BM Operating handle Compressed air inlet Vibrating cutting blade It is not generally practical to remove a bonded panel for later refitment such that 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 7 TC H STRUCTURE The front crash structure consists of an upper and lower moulding bonded together and supplied only as an assembly It i
553. sembly of the rear toe link refer to sub section DE A Smear the shank of each pivot bolt with PBC grease Apply Permabond A131 A912E7034 to the threads of any bolts tapping directly into the alloy hub carrier except early type hub carriers with tapped holes for the brake caliper mounting plate fixings see sub section DE 5 Apply Permabond A130 A912E7033 to the threads of the lower wishbone front pivot bolts weldnuts Coat the joint faces of the hub carrier with any steel component e g swivel joint plinth camber shim plates etc with Duralac MSDS anti corrosive jointing compound A111C6017 and assemble whilst the compound is still tacky The lower ball joint pin must be tightened into the plinth before fitting the plinth to the hub carrier Take care to refit the original camber adjustment shimpack Lubricate the ends of the damper eye bushes with rubber grease Before re fitting the driveshaft first renew the round section circlip A100R6001F on the end of the inboard joint spigot shaft Also check the condition of the transmission output seal and renew if necessary Lubri cate 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 shaft assembly into the transmission with the lubricated circlip fitted on the end of the spigot shaft Press the C V joint into the differential gear splines un
554. shift light Lap times incl memory and split Acceleration times Last corner and straight line speeds A full instruction booklet is supplied with the kit 1 Remove the standard tachometer and substitute the Tach Timer Level 1 instrument Connect to existing harness plug 2 Remove the steering column lower cowl and cut a 7mm hole in the RH side and a 12mm hole in the LH side to mount the driver push button and rotary switch 3 Cuta small 4mm wide slot into the lower cowl from the top mating face on both sides in order to allow routing of the sensor cable 4 From the access hole in the underside of the fascia between the steering column and centre divide withdraw the harness spur with the black 12 terminal square block connector Plug in the new switch and lap sensor harness and feed through the dash hole into the column shroud area 5 Mount the push button and rotary switch to the column shroud and connect the harness Fit the shroud and route the sensor cable out of the appropriate slot 6 Fit harness clips A100W6353F beneath the instrument rail as shown in the diagram with 4 under the passenger side and 2 under the driver s side Also fit two along the dash top towards the passenger side post Fit one tie wrap A082M6556F harness clip to each A post vertical face 7 Clip lap sensor cable under the instrument rail and cable tie the infra red sensor securely to the A post tie Your kit is now ready for use a
555. side of the engine bay Page 25 EG Lotus Service Notes 340R Fuses amp Relays The main fusebox is located in the pas senger footwell and is protected by a clear plastic cover 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 a fuse extractor tool A relay block adjacent to the fusebox houses eight relays with a further two relays located nearby Fuses Slot Rating Circuit Slot Rating Circuit 1 3A Rear fog lamp 12 25A Cooling fan 2 3A Alarm 13 3 75A Brake lights 14 30A Aux sockets 4 15 Wiper motor 15 5 Reverse lamp 16 5A Sidelamp LH 6 7 5A Direction ind 17 5 Sidelamp RH 7 10 Ignition services 18 25A Heated screen 8 75 Horn alarm 19 instruments 20 7 5A Dip LH 9 10A Hazard lamps 21 7 5A Dip RH 10 7 5A Horn 22 15A Main beam 11 Relays A Main beam E Rad fan J Wipe wash B Sidelamps F Rear fog K Hazard flash C Dip beam G Horn D Heated screen H Auxiliary Engine management fuses relays and p ENGINE diagnostic connector plug are mounted on the MANAGEMENT cabin rear bulkhead protected by an access panel retained by threaded fasteners Fuses Slot Rating Circuit 1 20A Fuel pump injectors 2 Engine management OBD2 3 T7 5A management Diagnostic canister purge idle control connector 4 75A Ignition coil Relays a Engine management igni
556. sill Two fixings at the rear edge of the liner into the clamshell One fixing at the rear inboard edge of the liner into the shear plate One fixing near the damper top into the longeron Withdraw both wheelarch liners Page 8 Fixing to rear longeron j Front fixings Fixing to shear plate Rear fixing 4 Disconnect the bowden cable from the engine lid latch plate and release unclip from its retaining clips 5 From inside each wheelarch remove the three fixings securing the shear plate to the longeron 6 Remove the screw securing the front bottom corner of each wheelarch to the sill 7 engine bay undertray diffuser is fitted release the five fixings securing the bottom rear edge of the clamshell to the undertray 8 Disconnect the rear harness at the LH rear of the luggage compartment and the harness connectors to the rear fog and reverse lamps 9 Remove the rear number plate and release the single fixing securing the clamshell to the rear tray bracket 10 Remove the fuel filler cap and release the four screws securing the fuel filler neck to the clamshell Remove the washer ring and withdraw the neck from the clamshell aperture 11 From inside the cockpit remove each rear corner speaker trim panel 5 Release the seat belt reel Remove the screw at the outboard top corner of the panel Remove the screw at the inboard edge also anchors the luggage net Pull the panel
557. sing use a new O ring fit retaining plate fit and tighten bolt to 5 Nm 41 Fit new clutch release shaft oil seal 42 Fit clutch release shaft and fork 43 Fit and tighten bolt to 29 Nm 37M1146A 25 Fit new differential oil seals in gear case NOTE Type amp oil seal use 18G1354 and 18G 1354 16 off seal use 180 1354 and 18G 1354 21 26 Fit input shaft oil guide plate in gear case 27 Fita new Belleville washer and selected circlip s 28 Fit selected circlip s 29 Fit new output shaft circlip in gear case 30 Fit selected circlip in differential bearing recess in gear case 31 Apply a bead of RTV silicone sealant to mating face of gear case REVISED 12 97 OVERHAUL 29 Lotus Service Notes Section GF WHEELS amp TYRES SECTION GF M111 ELISE Sub Section Page General Description GF 1 2 Winter Tyres amp Snow Chains GF 2 4 Emergency Punctured Tyre Inflator GF 3 4 Security Wheelnuts GF 4 5 1999 3 baden Lotus Service Notes Section GF F 1 GENERAL DESCRIPTION The single piece light alloy roadwheels in various styles are fitted with Pirelli P Zero tyres engineered to provide the optimum balance of ride and handling characteristics Pirelli Zero are the recommended tyres for use on the vehicle under normal road conditions order to fully exploit the dynamic qualities and packag ing opportunities the wheel and tyre sizes a
558. sis front crossmember and is fitted with the damper rod lowermost in order to minimise unsprung weight In order to protect the alloy hub carrier from the effects of electrolytic corrosion it is important to ensure that the joint faces with any steel components are coated with the specified jointing compound before assem bly CG 2 GEOMETRY amp 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 suspen sion repair or if excessive tyre wear is evident or if steering difficulties are encountered Before any measure ments or adjustments are made it is essential first to set the vehicle to its mid laden ride height approximating to driver and passenger and tank of fuel Ride height for geometry check front 140 mm below front end of chassis siderail rear 140 mm below rear end of chassis siderail Alignment 0 2 mm toe out overall 0 0 2 mm 0 03 toe out overall 0 0 03 Camber 0 1 0 1 0 2 Max side side 0 2 Castor 3 8 0 27 Max side side 0 2 Steering axis inclination 12 nominal Alignment Wheel alignment refers to the parallelism of the wheels when viewed from above and is crucial to vehicle stability handling and tyre wear
559. sive fuel temperature with the consequent risk of vapour locks When the ignition is switched on the engine management ECM energises the fuel pump which will continue to run for as long as the ECM receives ignition pulses from the ignition module engine cranking or running If no ignition pulses are received the ECM switches off the pump either 2 seconds approx after the ignition was switched on or about 10 seconds after a stall A safety inertia switch is incorpo rated into the fuel pump electrical circuit and operates in a severe impact indicative of a vehicle collision to switch off the fue pump feed and minimise the fire risk The switch is located to the rear of the air filter housing and is reset once tripped by pressing the rubber button on the top of the switch A roll over valve is mounted behind the fuel filler neck and is connected between a breather spigot on the neck and the charcoal canister This valve allows venting of the tank under normal circumstances but prevents fuel spilling from the vent pipe if the vehicle is inverted in an accident The evaporative emissions control system EECS prevents untreated fuel vapour from the tank reaching the atmosphere by routing the tank vent pipe from the roll over valve to a vapour storage charcoal canister mounted at the left hand side of the engine bay When the engine is stopped fuel vapour from the tank is absorbed by a bed of charcoal in the canister When the engine is running t
560. small D section hollow rubber weir is stuck to the front shut face of the door 15 mm from the outer edge of this surface Double sided tape is used af ter the surfaces have been degreased and primed with PP Primer 3842 Weir seal Page 19 n BN Lotus Service Notes Sectio BN 11 DOOR LATCH MECHANISM 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 through 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 links and a relay lever The interior release handle is mounted forward in 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 Relay lever Exterior release handle assembly button Interior release control rod Door latch mechanism Bracket door beam rear Exterior rear end to door shell lock control rod To replace interior release handle Remove the release handle trim panel by releasing the two screws in the panel front edge and unhooking the panel from the door and over the handle Remove the three screws securing the han
561. solenoid valve 24 Vacuum reservoir A cusa 2000 03 SECH E Lotus Service Notes Exige Engine Management The engine management electronic controller is common with the Esprit V8 and uses some of that model s components including Idle Air Control IAC valve mounted on the rear of the engine and connected by hose between the intake airbox backplate and ports in the underside of each inlet manifold tract Ignition Coil Pack one of the two identical V8 coil packs mounted on the rear of the cylinder head Electronic Control Module ECM mounted on the cabin rear bulkhead controls engine management systems including fully sequential injection and direct ignition Manifold Air Pressure MAP and Barometric pressure BARO sensors mounted on the engine bay LH wall A vehicle speed signal is provided for the ECM from a new wheel speed sensor mounted on the RH rear hub carrier The LH hub carrier sensor is retained for speedometer data Note for reference that the 340R uses only the LH sensor but splits the signal to speedo and engine ECM in the instrument controller Other engine management components are as standard Elise The OBD2 On Board Diagnostics version 2 connector socket is located within the electronics box on the cabin rear bulkhead For fault diagnosis the Tech 1 tool including the Esprit V8 cartridge should be plugged into this socket and any trouble codes read in conjunction with
562. speed sensor to its plinth With the car on a level surface top up the transmission oil to the filler level plug hole Driveshaft C V Joint and or Gaiter Replacement The outboard joint is available as a separate part whilst the inboard joint is supplied complete with the driveshaft Gaiter kits are separately available for both joints 1 2 Remove the driveshaft assembly from the car see above Cut off the gaiter retaining clips from both joints and slide the gaiters along the shaft The outboard joint is retained by a round section circlip on the end of the shaft To remove the joint hold the drive shaft in a vice and use a soft mallet to tap the joint over the circlip and off the shaft If the joint is reluctant to move use a brass drift on the front face of the inner race CAUTION Do not attempt to remove an outboard joint without first removing the shaft assembly from the car Unless the shaft is securely retained e g in a vise attempts to remove the outboard joint may result in the inboard joint becoming disassembled Slide both C V joint gaiters off the driveshaft Cleaning amp Inspection 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 interchang ing 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 tha
563. splay an artificially low reading Dipstick The dipstick is identifiable by Oil filler cap its yellow loop handle and is located at the right hand rear of the engine Withdraw the dipstick and wipe with a paper towel Re place the dipstick pressing firmly to make sure it is fully seated and withdraw again to inspect the oil level The correct level is to the upper mark on the dipstick Topping Up f topping up is necessary remove the oil filler cap from the cam cover and in order to allow the crankcase to venti late remove the dipstick Add a suitable quan tity of a recommended engine oil see Sec tion OG taking care not to spill any oil onto engine or electrical components use a funnel if necessary Dipstick The difference between high and low dipstick marks is equivalent to 1 0 litre 1 8 imp pt Allow several minutes for the oil to drain through to the sump before re checking the oil level Do NOT overfill or the oil will become aerated and its lubricating properties degraded Refit the filler cap and turn clockwise until secure 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 Sched ule On cars so fitted the engine bay undertray diffuser must be removed for access to the engine sump and filter The drain plug is located at the right ha
564. ss of the panel illu mination and also resets the trip distance re COCKPIT CENTRAL corder DIVIDE SWITCHES In order to zero the trip display with the ignition switched on press the reset button briefly less than one second The brightness of the instrument illumina FEN tion is also controlled by this switch To cycle Panel illumination through the four levels of brightness switch amp trip reset on the ignition press and hold the button and release at the desired setting Note that with the lights switched on panel illumination is Side marker lamps automatically at the brightest Side Marker Lamps Switch The second switch down in the cockpit Headlamps switch central divide functions only with ignition and Switches on the front and rear side lamps to gether with the instrument illumination The sidelamps will default to the off condition each time the ignition is switched off Rear fog lamps Headlamps Switch Heated The third switch down the cockpit cen tral divide functions only with ignition and when the side marker lamps have been re quested by the sidelamps switch Pressing the headlamps switch under these conditions switches on the headlamps in main beam or dip mode dependent on steering column le ver switch position Note that dip beam is provided by the projector lamp mounted in each acrylic covered front lamp cluster These lamps remain lit when main beam is selected and the driving lamps
565. ssure or after engine switch off a vacuum reservoir with integral non return valve is mounted within the RH rear wheelarch accessible after removal of the wheelarch liner The sector rack and pinion temperature control is equipped with an electrical micro switch closed at the full cold position to operate a solenoid valve and supply the water valve actuator Note that the default position of the flaps no electrical power or vacuum supply is screen flap open footwell flap closed fresh air intake open The water valve default is open The vacuum pipes from reservoir to solenoid valves and from water valve soleinoid valve to actuator run along the outside of the RH chassis siderail Note that the vacuum supply to the three identical solenoid valves is to the central of the two ports on each valve The wiring harness to each of the three identical solenoid valves is colour coded with tape with yellow water valve outermost red re circ central and blue footwell innermost The fourth solenoid is of a different design to operate the screen flap Va m m Vacuum reservoir Vacuum take off from intake plenum Elise or inlet manifold Exige lenoid va Screen Footwell Re circ Water valve Water valve Screen flap actuator Footwell flap actuator uu Footwell fe flap Re circ flap Re circ flap actuator 2000 04 Eb Lotus Service Notes Section PH LHD shown Yellow harness tag water valv
566. st be recovered using suitable equipment connected to the service ports at the right hand front of the engine bay 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 Tighten the trianry switch to 10 13 Nm Inlet connection from condenser Outlet to evaporator Receiver drier Trianry switch Mounting clamp inda 2000 04 Lotus Service Notes Section PH PH 12 EXPANSION VALVE The expansion valve is fitted onto the evaporator pipes at the front of the a c housing in the climate chamber and is accessible from within the front services compartment To replace the valve 1 M5 clamp screw x2 Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of the engine bay 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 Release the two 5 screws 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 gt M6 clamp screw fe O ring seal Top clamp plate
567. st monitoring the temperature and if it continues to rise switch off and seek qualified assistance After a heavy snowfall ensure that the radiator cooling inlet and outlet grilles in the front body are cleared of snow before driving the car or overheating may occur Odometer Asix digit odometer total distance recorder reading is displayed at the top left hand corner of the panel and is calibrated in the same units miles or kilometres as is the speedometer Trip Recorder A four digit trip recorder is provided at the top right hand corner of the panel calibrated in the same units as the speedometer Below 100 the display includes tenths 0 0 99 9 and over 100 whole units 100 9999 In order to zero the trip display switch on the ignition and press for moment less than one second the Se SE EE TE SOE IM OVE MT EE Page 23 E Lotus Service Notes 340R 22 uppermost switch on the cockpit divider Note that this dual function button also controls the panel illumination see Instrument amp Switch Illumination The cockpit central divide contains five push button switches each of which is pressed once to switch on and pressed a second time to switch off A symbol is positioned above each switch to indicate its function and is backlit blue when the ignition is switched on Panel Illumination amp Trip Reset The topmost switch in the cockpit divide controls both the brightne
568. stalling and to maintain idle speed when the additional load is placed on the engine a compressor engagement command is preceeded by a signal to the engine management ECM to open the idle air control valve accordingly 2000 04 DEER Lotus Service Notes Section PH 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 compresser releases heat to the surrounding air via the condenser finning with airflow boosted by two electric fans mounted below the con denser and ram air flow caused by vehicle movement Receiver Drier The receiver drier unit mounted on the right hand side of the radiator duct houses a screen sack filled with desiccant to absorb traces of moisture and other contaminants from the refrigerant A sight glass built into the top of the receiver drier enables a quick check of the refrigerant charge in the system If the refrigerant charge is low a stream of bubbles will be visible at the sight glass Note Aclear sight glass may indicate that the system is correctly charged or completely empty although the latter situation is usually accompanied by oil streaks A trinary switch on 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 damage from too high a pressure or from compressor oil starvation caused
569. steel guide sleeve and withdraw the bush boot from the caliper Pull the boots off the top steel guide bush and slide out the bush from the caliper e Clean the guide bores in the caliper body with brake cleaner Lubricate the new bushes and boots with silicone grease provided in the repair kit and reassemble into the caliper in reverse order to disassembly f Refit the caliper to the adaptor plate using Permabond A134 on the threads of both bolts torque tightening the two fixings to Upper M10 bolt 45 50 Nm 33 37 Ibf ft Lower 8 caphead 26 30 Nm 19 22 Ibf ft g Reconnect the parking brake cable and operate the footbrake to reposition the pads before driving the car iib 1998 03 Lotus Service Notes Section KF ENGINE COOLING SECTION M111 ELISE Sub Section Page General Description 1 3 Maintenance KF 2 3 Drain Refill Procedure 4 Radiator amp Cooling Fan KF 4 6 Radiator Fan Control KF 5 8 Radiator Feed amp Return Pipes KF 6 8 Water Pump amp Thermostat See Section EE Page 1 Lotus Service Notes Section KF Thermostat Closed Heater matrix Heater feed pipe Thermostat housing Heater return water rail Radiator by pass circuit Thermostat Open Radiator inlet hose Radiator Radiator feed pipe Engine outlet spout Radiator 4 lt outlet hose CS 774 2 D 2 SH 5 Radiator return pipe A 5 Radiator return rail Page 2 E Lotus Se
570. stem fitted height ior ae ha PORE SS 38 95 to 40 81 mm Service limit 41 06 mm K16 engines Valve stem diameter Inlet 2 Abee 5 952 to 5 967 mm Exhaust code ere Nue 5 947 to 5 962 mm Valve guides Inside diameter 6 000 t0 6 025 mm Valve stem to guide clearance Inlet ce vene 0 033 to 0 063 mm Service 0 07 mm Exha st su o b Ee 0 038 to 0 078 mm Service limit 0 11 Valve stem fitted height 225 2 hw eae eet 38 93 to 39 84 mm Service limit 40 10 mm 2 DATA TORQUE amp TOOLS ENGINE esee Valve guides Fitted height K8 10 3 16 22 eau eats ee dye eee 6 0 mm Valve seats Angle 45 Width Not triple angle valve seats Inlet and exhaust 1 5mm Triple angle valve seats E cb ees oie eid Mb eet eae ee 1 0 to 1 4mm Exhaust 1 4 to 1 8 mm Valve face angle up DEDE 45 Exhaust 26 6 heh ce sh bb ete p 45 Crankshaft Crankshaft end float 0 10 to 0 25 mm Service limit 0 34 mm Thrust washer halves thickness 2 61 to 2 65 mm Main journal tolera
571. stment catered for by an adjustable length tie rod between transmission end bellcrank lever and selector shaft With the gearchange mechanism assembled and the transmission in neutral 1 Fore aft position Viewed from the side the lower part of the gear lever before the rearward bend should be vertical or leaning very slightly to the rear If necessary slacken the two fixing bolts on the transmission end cable abutment bracket and move forwards or back wards to achieve the specified lever po sition Tighten the two bolts Front M12 bolt 77 Nm Rear M10 bolt 45 Nm Cable abutment bracket Page 3 2 Crossgate position Viewed from behind the gear lever should be vertical If nec essary adjust the length of the transmis sion end bellcrank tie rod The nominal length between ball joint centres is 70 mm The tie rod is RH threaded at both ends so that before an adjustment can be made the lower ball joint must be released from the selector shaft lever Adjustments to the tie rod length can be made only in increments of one thread pitch Lengthen the rod to move the fever position to the left Shorten to move the lever to the right Ensure that there is similar thread engagement into each of the two ball joints Refit the ball joint to the lever and tighten to 4 7 Nm 3 5th 6 reverse crossgate stop An adjustable stop bolt is provided to limit the gear lever crossgate move ment to the right 5th and
572. strip to the carrier using Loctite 480 adhesive 4 Release the screws securing both tongue strips and carriers and clean the mating surfaces of the tongue carriers and header rail with Betaclean Apply a thin bead of black Silastic to the underside of the carriers and fit the carriers and tongue plates drilling the remaining pilot holes and retaining with the screws Seal the top end of the door weatherstrip to the the header rail with a small bead of Silastic 5 Cleanthe top surfaces of the tongue strips with Betaclean before applying the self adhesive gripper tape Trim the ends of the tape to match the profile of the carrier moulding 6 Fitthe D section header rail seal abutting the front edge of the carrier moulding BN 15 DECAL POSITIONING Self adhesive decals are used on the rear transom and on the dash Before fitting a decal the surface must be degreased with an acetone cleaner and allowed fully to dry Rear Transom gi LOTUS 5mm gt YOO 9 Page 29 ES Lotus Service Notes Section BN Dash Panel Dash top to plastic insert jointline BN 16 REAR BOOT BULKHEAD To create a protective wall and to provide a mounting for the optional rear boot bag and lid an alloy bulkhead is fitted between the engine and the rear luggage compartment A bulkhead may be fitted to a car built without one without removing the rear clamshell as follows Clamshell gutter Boot bag U clip lo
573. t MANUAL GEARBOX 0 0 mesh with the helical gears and the spur gears mesh with those of the adjoining element gear assembly Axial thrust of the helical gears is controlled by a combination of thrust washers and needle roller bearings located at each end of and between the two gears Type B The assembly comprises a final drive gear bolted to the differential casing two helical side gears splined to the drive shafts and four pairs of element gear assemblies arranged at ninety degree intervals within the differential casing and running parallel to the side gears Each of the element gear assemblies comprises two helical gears of unequal length the long gears are in constant mesh with the helical side gears splined to the drive shafts and also with the short gears of the adjoining element Axial thrust of the helical side gears is controlled by thrust washers located between the end of each gear and the differential casing and by a thrust washer and friction washer located between the two gears OPERATION With the exception of reverse all gears are in constant mesh Forward ratios are obtained by locking a gear to its shaft using its individual synchronizer hub and sleeve Reverse gear is obtained by engaging reverse idler gear with the reverse gears changing the direction of rotation of the output shaft When a forward gear is selected the synchronizer sleeve presses the synchromesh female cone into contact with a correspond
574. t noting the spacer washers fitted at the top end Disconnect the anti roll bar drop link from the lower wishbone and remove the lower wishbone front pivot bolt Withdraw the anti roll bar with its mounting blocks Remove the lower wishbone rear pivot bolt from within the footwell and withdraw the wishbone 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 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 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 the top wishbone rear bush was originally common with all other front wishbone pivot bushes but was changed during 98 to a non interleaved bush identified by a blue paint mark Top and bottom swivel joints are identical and may be replaced if necessary using a suitable press The road spring may be removed from
575. t the passive immobilisation security feature may operate dependent on type of alarm fitted and disable the ignition and starter circuits press the appropriate transmitter key button as directed in sub section MN 1 B To remove the key turn fully counterclockwise to 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 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 Always remove the key when leaving the car in order to lock the steering column and to guard against a flat battery 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 Do not leave the ignition key in position when leaving a parked car to protect against theft and to ensure the safety of any children remaining in the vehicle TELL TALE LAMPS Bulb Check In order to check that the warning systems are operative all the tell tale lamps except the Alarm tell tale see sub section MN 1 should light for about six seconds when the ignition is turned on If any lamp should fail to light it is possible that the bulb or warnin
576. t and anti roll bar drop links to 45 Nm Lower Wishbone Front Pivot Detail Flanged spacer tube Bonded reinforcement plate Wishbone pivot bolt Bonded inserts M5 clamp bolt Drop Link Detail Lower wishbone Anti roll bar drop link Anti roll bar end plate 5 Page 22 Lotus Service Notes Section XA XA 11 OIL COOLER KIT A111K0037S The oil cooler kit is recommended for use with the 190 VHPD engine and includes a 9 row cooler mounted to the front crash structure beneath the radiator duct into the floor of which are cut air feed holes with air exhausting from the oil cooler via an aperture in the revised front undershield The oil cooler feed and return hoses are routed from a new oil filter housing via the RH sill and front wheelarch Oil Cooler Kit Contents Description Part no Qty Oil Cooler Kit 111 00375 1 comprising Oil Cooler A111K0036F 1 Oil Filter Housing A111E6146F 1 90 Connector oil pressure switch A111E6147F 1 Hose oil cooler feed A111K0035F 1 Hose oil cooler return A111K0034F 1 Mounting Bracket oil cooler A111K0032F 1 Duct oil cooler A111K0039F 1 Undertray front A111B0400F 1 Convolute Hose Protector A082V7779V 300mm Grommet cooler hose A079U6033F 4 Miscellaneous Fixings Convolute protection Oil filter housing Cut holes in body post Air inlet holes Sill baffle Oil cooler feed hose Hoses clipped to top of wheelarch liner Oil cooler return hose Oil cooler O
577. t box fit the floor into position between the longerons before inserting the three 6 4 mm 1 4 rivets each side to secure the longeron and boot floor if applicable to the subframe Fit the M10 caphead screw and washer to secure the roll over bar stay and longeron to the damper mounting tapping block 6 Fitthe exhaust heatshield electrical component plate and other components in reverse order to removal Tapping block Longeron 6 4mm rivet Chassis siderail end flange Primer and Betaseal bead N Rear subframe Page 6 eS Lotus Service Notes Section BM BODYCARE amp REPAIR SECTION 111 ELISE Sub Section Page General Description BM 1 3 Lotus Composite Body Features BM 2 3 Bodycare BM 3 3 Accident Damage Assessment BM 4 5 Body Panel Bonding Materials BM 5 6 Replacement of Bonded On Panels General BM 6 9 Front Crash Structure BM 7 10 Windscreen Frame BM 8 12 Sill Panels BM 9 16 Rear Bulkhead Panel amp Capping Rail BM 10 18 Page 1 E Lotus Service Notes Section BM Principal Body Components Windscreen RH door frame scuttle shell RH sill Front Engine cover compariment lid aluminium alloy Crash structure Chassis structure aluminium alloy Page 2 Lotus Service Notes Section BM BM 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 rig
578. t bush Pedal pivot bushes thrust washers used as spacer ES N 2272222272 4 AP EP A VU AP 222 22222 6 11 2 242222 7 ESSA INNO et ett 2 2 2 2 2 L 4 Pushrod trunnion Scuttle bracket Clutch pedal Brake pedal Throttle pedal jesl Page 14 Lotus Service Notes Section JH Clutch Brake 8 On re assembly note that no lu pedal pedal bricants are used in conjunction with plastic bushes but that a spe cial Dow Corning DC33 Medium gt i s G grease A111F6016 is used on the brake and clutch pedal trunnions Take care to correctly identify the brake and clutch pedals The bore for the pushrod trunnion is offet on WE the brake pedal towards the pivot 7 reverse order to removal adjusting the brake pedal pushrod as detailed in sub section JH 7 and the clutch pedal in a similar manner The throttle pedal upstop should be adjusted as follows Adjust the pedal upstop for a throttle pedal height approximately 30mm lower than the clutch and brake pedals Adjust the length of the ball jointed pull rod to achieve a gap of 20mm between the outer cable abutment and the inner cable pivotting link on the multiplier lever Adjust the cable slack at the engine end abutment as detailed in section EMN or Lotus Check operating instructions Adjust
579. t 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 BN 4 BN 5 and dash panel BN 12 Remove the clamshell mounting bracket at the bottom corner of the windscreen Remove the cant rail striker from the top of the sill B post to the roll over bar and the door latch striker pin Remove the speaker panel from the cabin rear corner and remove the engine lid release cable from the sill panel Use a sealant cutting knife to cut the adhesive bead between sill and chassis body panels Note n 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 rear bulkhead panel may need to be released from the chassis sufficiently to allow cutting of the sealant between sill and bulkhead panel Alternatively the sill can be cut as necessary to allow its removal and then the remaining sill flange removed with the improved access The top and bottom edges of the sill centre section fit into grooves in the chassis side frames 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 fr
580. t the LH rear of the luggage compartment and the harness connectors to the rear fog and reverse lamps 9 Release the fixings securing the bottom edge of the clamshell to the tank bay closing panel and that securing the front of each wheelarch to the body sill 10 From inside the cockpit release the clamshell front fixing from inside each B post 11 From the door aperture remove the two fixings securing the front edge of the clamshell SCH 2000 03 Exige Gutter to engine bay surround post inboard fixing Support plates to longerons plate recess to tray extension Wheelarch to sill Tank bay closing panel to clam lower edge 12 Carefully ease apart the two front sections of the clamshell as the shell is manouvered rearwards off the car 13 Refit the clamshell in reverse order to removal Rear Aerofoil The rear aerofoil is a hollow glassfibre composite moulding with integral endplates The aerofoil is secured to two moulded polyurethane plinths via M5 bolts through the plinth top flange into captive nuts in the aerofoil whereas the plinths are fixed to the body by two M6 studs moulded into the bottom of each plinth with nuts fitted inside the clamshell Loads from the aerofoil plinths are transferred into the clamshell support plates via alloy angle brackets Roof Section The roof panel incorporates an air intake duct feeding into a corresponding duct in the tailgate The single hinge f
581. t 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 On the outboard ball type joint 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 On the inboard tripod type joint examine the fit between the rollers and the housing Excessive free play roughness on either roller or track surfaces damage to the bearings or trunnion call for joint re placement If the joint is found to be serviceable it must be repacked with special grease as follows Outboard joint 1 sachet A100R6009 52 ml boot kit contains 2 sachets Inboard joint 2 sachet A100R6010 62 ml boot kit contains 3 sachets Replace the circlips securing the inboard joint to the transmission and the outboard joint to the shaft New circlips should always be used to ensure security of joint retention Note that the circlip for the outboard joint is supplied in the boot kit for either joint but that the inboard joint circlip shouid be ordered sepa rately Tape over the shaft outboard splines to prevent damage to the new gaiters and slide the inboard gaiter and small retaining clip onto the shaft followed by the outboard gaiter small clip and gaiter Remove the tape Outboard Joint
582. t tyre depot 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 exceed ing 30 mph 45 km h The aerosol should not be used for large holes or repairs or when the tyre sidewall has been damaged or if the tyre has been displaced from the rim The aerosol should be carried at all times in the stowage bracket provided in the front services compartment never in the passenger compartment Directions for use of the aerosol As soon as a puncture is suspected pull off the road atthe first safe opportu nity If possible avoid driving on a deflated tyre or irreparable damage to the tyre may be caused Before using the aerosol carefully read all the instructions on the canister or on any literature accompany ing the product The following instructions apply to the use of Holts Tyreweld 1 Removethe object causing the puncture and position the wheel with the puncture site lowermost Deflate the 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
583. tage reposition clamps as necessary to enable timing plates to be fitted 3 Place a strip of Plastigage across each inlet camshaft joumal on camshaft carrier and position front inlet camshaft and VVC housing in camshaft carrier 4 Position rear inlet camshaft and VVC housing in camshaft carrier 5 Fit and lightly tighten a slave M6 bolt to retain front and rear VVC housings to camshaft carrier 6 Remove clamps 18G 1770 CAUTION During the following operations it is essential to ensure that front and rear inlet camshafts are retained in their respective VVC assemblies and the camshaft carrier 7 Invert camshaft carrier and fit to cylinder head 12M3503 8 Fit 32 bolts noting that 4 longest bolts are fitted at each end of camshaft carrier 9 Using sequence shown progressively tighten bolts 10 Nm 0 CAUTION Do not rotate camshafts 10 Progressively slacken then remove 32 bolts securing camshaft carrier to cylinder head 11 Carefully release camshaft carrier from cylinder head 12 Lift camshaft carrier together with front and rear inlet camshafts off cylinder head CAUTION Ensure that exhaust camshaft AN is retained in cylinder head 13 Invert camshaft carrier OVERHAUL 45 ENGINE 1861770 18 1770 2 1861770 18G1770 1 X 16 12M3518A 14 Assemble clamps 18G 1770 to front and rear inlet camshafts and VVC assemblies fit camshaft gear bolts and washers to retain cl
584. tal base which also act as the valve spring seat on the cylinder head Exhaust valves fitted to later engines are of the carbon break type A machined profile on the valve stem removes any build up of carbon in the combustion chamber end of the valve guide thereby preventing valves from sticking These valves may be fitted to all early engines The stainless steel cylinder head gasket has moulded seals around all coolant breather and oil apertures and has steel cylinder bore eyelets Compression of the gasket is controlled by limiters at each end of the gasket The cylinder block is fitted with damp cylinder liners the bottom stepped half of the damp liner being a sliding fit into the lower part of the cylinder block The liners are sealed in the block with a bead of Hylomar applied around the stepped portion of the liner The seal at the cylinder head is effected by the cylinder head gasket with the liner top acting as a break between the combustion chamber and gasket The aluminium alloy thermal expansion pistons have a semi floating gudgeon pin which is offset towards the thrust side and has an interference fit in the small end of the connecting rod Pistons and cylinder liners are supplied in two grades Big end bearing diametric clearance is controlled by three grades of selective shell bearing The five bearing eight balance weight crankshaft has its end float controlled by thrust washer halves at the top of the central m
585. tand proud of combustion face of head on completion of recutting operation 56 OVERHAUL 3 Lap each valve to seat using fine grinding paste 4 Apply Prussian Blue to valve seat insert valve and press it into position several times without rotating Remove and check valve for even and central seating Seating position shown by blue should be in centre of valve face 3531 5 Check valve stem fitted height A K8 New 38 95 to 40 81 mm Service limit 41 06 mm K16 New 38 93 to 39 84 mm Service limit 40 10 mm If valve stem fitted height is above service limit fit new valve and re check if still over limit renew valve seat insert All engines 6 Remove all traces of grinding paste on completion K16 VVC housing gaskets remove M I 1 Secure VVC housing and camshaft in a Soft jawed vice with camshaft positioned upwards CAUTION Only tighten vice sufficiently to retain housing damage to mechanism wili result if vice is overtightened 2 Taking care not to allow camshaft to become separated from VVC mechanism remove clamp 18G 1770 and timing plate 18G 1770 1 front 18G 1770 2 rear 3 Remove and discard VVC housing gasket 4 Repeat above procedures for remaining VVC housing gasket K16 VVC housing gaskets refit NOTE To assist correct location of VVC housing gasket in its fitted position apply a light film of grease to gasket face of VVC housing 1 Lubr
586. tarted 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 Seat Belt Tell Tale The red seat belt tell tale is provided as a reminder and will remain lit until the driver s seat belt is Page 10 sl Lotus Service Notes Section MN Lotus Service Notes Section MN fastened Both driver and passenger should always wear the seat belts no matter how short the journey Main Beam Tell Tale This lamp glows blue whenever the headlamp main beams are operating Alarm Tell Tale The red vehicle security alarm tell tale indicates the status of the alarm immobilisation system For full details see sub section MN 1 Vehicle Security Alarm Battery Charging Tell Tale 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 Catalyst Overheat Tell Tale Japan only This tell tale will glow red if an engine fault occurs which results in the t
587. te and are bonded to the chassis structure using an elastomeric adhesive The front and rear body sections are each single piece composite mouldings fixed to the chassis structure with threaded fasteners Two main chassis siderail extrusions 210mm deep and 100mm wide run along each side of the passen ger compartment between the front and rear suspension mountings splaying outwards towards the rear until the fuel tank crossmember behind the passenger cell At this point the siderails curve inwards around each side of the engine bay to provide platforms for the engine mountings The passenger cell is further stiffened by sill extrusions secured beneath the siderails with the flat floor panel reinforced with ribbed transverse channel sections running across the inside of the tub which also provide seat mountings At the rear of the passenger cell an open bottomed crossmember uses a detachable swaged closing panel to house the steel fuel tank with a further extruded crossmember joining the bottom of the siderails at the rear of the fuel tank bay and providing pick up points for the front pivots of the rear lower wishbones Note that the fuel tank bay closing panel contributes to the structural integrity of the chassis such that the vehicle should not be operated without the panel fitted The rear ends of the siderails are joined behind the engine bay with a galvanised sheet steel fabricated subframe which provides mountings for the rear suspension p
588. te organising authority Full tyre specification is detailed in sub section XA 15 Note that the tyre tread pattern is directional with the correct rotation marked by an arrow on the sidewall For cars used predominately on public roads it may be preferred to fit Elise 111 specification Pirelli Zero tyres with appropriate suspension geometry see front and rear suspension sections 2000 02 ar EG Lotus Service Notes 340R 3 H All the steering components used on the 340R as standard Elise except the steering wheel centre which is trimmed in blue Alcantara and the rack positioning plates which are sport specification to suit the lowered ride height The Sport removeable wheel may be fitted for track use For full details refer to section HE and XA 340R J BRAK The 340R uses the drilled cast iron discs and brake pads as fitted to the Elise 111S For full details refer to section JH 340R K COOL The cooling system is unchanged from standard with the exception of the radiator duct crash structure which is similar in concept but reshaped A front mounted oil cooler is an optional fit 340 L Y The fuel system is based on that of the standard Elise but the f el tank filler spigot is angled more acutely to clear the cabin rear bulkhead New hoses connect the tank to the filler neck which uses a flush fitting lockable cap As the cap does not incorporate the safety pressure relief function provided by t
589. ted Camshaft timing belt manual tensioner refit NOTE On engines fitted with an automatic tensioner tensioner 15 fitted when timing belt is fitted 12M35198 NOTE K16 non VVC engine illustrated On VVC engines tensioner spring and pillar bolt are supplied with replacement timing belt 1 Fit timing belt tensioner and pillar bolt tighten bolt to 25 Nm 2 Connect tensioner spring to tensioner and pillar bolt CAUTION Ensure correct spring is fitted K8 and K16 non VVC engines spring is fitted with a sleeve K16 VVC engines spring is not fitted with a sleeve 3 Tighten tensioner backplate screw to 10 Nm to retain tensioner in released position 76 OVERHAUL ENGINE 4 Check correct alignment of timing marks crankshaft gear to mark on oil pump 5 Fit and adjust a new camshaft timing belt CAUTION K16 VVC engines Remove and discard tensioner spring and pillar bolt on completion of camshaft timing belt adjustment Distributor K8 and K16 non VVC engines if fitted refit K8 1 Fit new O ring to distributor 2 Position distributor and tum rotor to engage offset drive align reference mark or centralise distributor and lightly tighten screws 3 Fit distributor cap and connect plug leads 4 Fit anti flash shield and rotor arm Use new rotor arm screw and tighten to 10 Nm 5 Fit distributor cap assembly 6 Place HT lead retaining plate and grommet in pos
590. ted PG1 with Rover publication RCL 0124ENG covering the description and overhaul of this transmission A conventional bevel gear differential is fitted for the Elise application The gearchange mechanism is different to that used by Rover with the two cables running beneath the power unit see sub section FG 2 The transmission serial number is printed on a bar code label fixed to the top of the clutch housing Serial number label FG 2 GEARCHANGE MECHANI The gearlever is spring biased towards 1 3 5 the 3rd 4th gear plane such that it must be moved against light spring pressure to the left before selecting first or second gear and against similar pressure to the right before selecting 5th or reverse gear An inhibitor device within the transmission selector mecha nism prevents the selection of reverse gear directly from 5th by requiring that the lever first be moved across the gate to release an 2 4 R E interlock 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 for the sideways movement The steel gearchange lever incoporates an integral pivot ball which pivots in a two piece nylon socket in an alloy housing The housing is mounted on a fabricated steel bracket which incorporates abutments for the two cables and is fixed to the cabin floor crossmembers Both gearchange cables run down the cent
591. tely this will in fact cause a deterioration in the protective properties of the paint film If a car is garaged good ventilation must be provided otherwise storage outside on a hard standing or under a carport is preferable Windscreen When washing the windscreen take care to lift the wiper blade only a small distance from the glass in order not to damage the wiper arm mechanism Wash the wiper blade with clean water Alloy Wheels Cleaning It is recommended that these are washed with the preparation as is used to wash the bodywork Use brush having only nylon bristles During the winter months particularly when salt has been used on the roads for the dispersal of snow and ice remove all wheels and wash thoroughly to remove all accumulated road filth Page 4 Rex Lotus Service Notes Section from wheels and tyres Upholstery Cleaning Cloth Upholstery Normal cleaning consists of an occasional light wipe over with a cloth dampened in a mild soap and water solution it is important that the cloth is only dampened not soaked Alternatively a proprietary upholstery cleaner may be used Leather Upholstery The leather should be wiped over occasionally with a cloth dampened in warm soapy water Use a mild non caustic toilet soap or soap flakes Repeat the operation using a fresh cloth and water only but avoid flooding the leather Finish by drying and polishing with a soft dry cloth The manufacturers of the leather do not recom
592. tensioner anti clockwise and align the centre of the indent on the tensioner pointer to the index wire CAUTION Ensure that pointer approaches index wire from above Should pointer go past index wire release tension completely and repeat tensioning procedure M124958 15 Ensuring that pointer maintains correct position tighten tensioner bolt to 25 Nm 16 Using crankshaft pulley bolt rotate crankshaft 2 turns clockwise and align camshaft gear timing marks CAUTION Do not use camshaft gears gear retaining bolts or timing belt to rotate crankshaft 17 Check that pointer is still correctly aligned with index wire CAUTION If pointer is not correctly N aligned carry out the following procedure 18 Slacken tensioner bolt until it is just possible to move the tensioner lever Using a 6 mm Allen key rotate tensioner lever clockwise until pointer is just above the index wire then rotate tensioner lever anti clockwise until pointer is correctly aligned with index wire 19 Ensuring that pointer maintains correct position tighten tensioner to 25 Nm 20 Using crankshaft pulley bolt rotate crankshaft 2 tums clockwise and align camshaft gear timing marks 21 Check that pointer is still correctly aligned with index wire 14 OVERHAUL 22 Ensure inserts are fitted in timing belt upper front cover 23 Fit timing belt upper front cover ensuring correct position of seal fit screws tighten screws and bot
593. th the exceptionally light weight contributed to by the exclusion of opening doors or a roof structure The principal body mouldings are as follows Cockpit Tub Single piece moulding includes the scuttle cockpit coaming and rear bulkhead Bonded to the chassis with elastomeric adhesive Side Closing Panels Closing panel between outboard top edge of tub and top of chassis side rail extending rearwards to form the engine bay side walls and provide support for the topshell Cockpit Side Screens The cockpit sides are made from translucent polycarbonate sheet bonded to the chas sis and upper side panels Topshell Single piece moulding includes the whole nose section cockpit surround and rear body deck Se cured with threaded fasteners Incorporates two removeable access panels at the front each of which is secured by four threaded fasteners The engine lid at the rear is fixed by nine threaded fasteners Sill Panels Run from behind each front wheel to sweep upwards ahead of the rear wheels Bonded to the chassis with elastomeric adhesive Side Intake Ducts Bolted to side closing panel to admit air into engine compartment Front Spoiler Splitter One piece moulding bolted to the topshell includes splitter panel beneath nose and twin deck aerofoils ahead of each front wheel Windscreen Frame One piece composite moulding similar in concept to standard Elise but excludes fascia top and accommodates shorter windscreen Engine Bay Rear Wall
594. the cant rail front foam seal is not caught beneath the roof material and is left exposed to form a weather seal with the door glass 4 Unfold the two roof tails and engage the pin in each tail with its keyhole slot in the body buttress Ensure that the pin is fully engaged before using the hexagonal key provided stowed in the corner panel behind the left hand seat to turn each cam pin to tension the roof Right hand pin clockwise Left hand pin counterclockwise Tensioning roof Roof bows erected 5 the two roof bows rearwards to their upright position to fully tension the roof Soft Top Roof Removal amp Stowage 1 Push both roof bows forwards to relieve the tension on the fabric 2 Use the hexagonal key stowed in the corner mE panel behind the left hand seat to release the Tucking in roof tail tensioning pins in the roof tails Turn the right hand pin counterclockwise Turn the left hand pin clockwise 3 Pull each tail backwards to disengage the pin from its keyhole slot fold the tail over and tuck the end beneath the elastic strap to protect the paintwork and glass from being damaged by the pin mecha nism ghs57 Page 3 Lotus Service Notes Section BN 4 Unclip the three press studs securing the roof to each siderail and pull the front edge of the roof forwards to release from the header rail retaining strip Lift off the roof fabric lay upside down and fold over each si
595. the matrix as determined by the position of the temperature selector knob When full cold is selected the control mechanism closes an electrical microswitch which operates a vacuum solenoid valve in order to supply a vacuum operated water valve to close the coolant supply to the matrix The water valve is fitted at the right hand bottom of the engine bay SES 2000 04 Engine coolant outlet pipe RH chassis siderail Water valve vacuum pipe RH rear lower wishbone AA Q Heater water valve ES 2 CONTROLS OPER AIRFLOW DISTRIBUTION The interior climate controls consist of three rotary controls for fan speed tempera ture and air distribution and two push switches a c switch Temperature Recirculation for air conditioning and air re circulation control switch Fan speed switch Distribution control Air Conditioning The left hand push button switches on the air conditioning but the engine must be running and a fan speed selected before the system will operate 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 amber tell tale in the switch button is backlit when the sidelamps are switched on to help locate the switch and brightens when the circuit is active Air Re circulation When the re circulation button is pressed a vacuum operated flap via a solenoid valve closes off the fresh air int
596. the pedal downstop so that full travel of the throttle butterfly can just be achieved without allowing the cable to be strained Viewed from above Cable abutment Throttle cable Throttle pedal Pedal pullrod Pivotting link Multiplier lever Torque Settings Nm Pedal box to chassis 9 Brake master cylinder to pedal box 28 Clutch master cylinder to pedal box 28 Brake pipes to master cylinder 15 1998 03 Page 15 Lotus Service Notes Section JH JH 9 CALIPER OVERHAUL The front brake calipers 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 The Brembo rear brake calipers 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 Caliper Sliding Pins The sliding bushes and sleeves of the Brembo rear calipers may be replaced without disturbing the hydraulic connection Top guide bush boots Top guide bush Lower guide boot Split plastic bush Lower guide sleeve a Disconnect the parking brake cable from the caliper 0 Remove the cap head securing the bottom guide bush to the caliper adaptor plate Remove the hex head bolt securing the top guide bush to the caliper adaptor and withdraw the caliper from the car with the brake hose still connected Slide out the lower
597. til a click indicates that the circlip has engaged in its location Pull on the body of the joint to check security After refitting the brake caliper press the brake pedal to reposition the pads before driving the car 14 The Service Schedule specifies that the security of the front and rear suspension is checked at each service 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 1999 01 Lotus Service Notes Section DE 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 lost Remove the bolt completely clean off all old adhesive with 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 Torque Settings Nm Upper and lower wishbone pivot bolts 45 Upper and lower swivel joints to plinth 55 Upper swi
598. tion Competition Style Seats amp 6 Point Competition Harness XA 3 8 Roll Over Bar Competition Reinforcement Kit XA 4 11 Hand Held Fire Extinguisher XA 5 14 Plumbed In Fire Extinguisher XA 6 15 Uniball Toe Link Kit XA 7 17 Road Spring amp Damper Set XA 8 18 Front Hub Clamp Bolt Set XA 9 21 Adjustable Front Anti Roll Bar XA 10 22 Oil Cooler Kit 11 23 Battery Isolator Switch XA 12 26 Removable Steering Wheel XA 13 31 Stage 2 135 bhp Engine Tuning Kit XA 14 33 Yokohama A038 R Competition Tyres XA 15 35 340R 340 PS Tonne Pack XA 16 36 340R Oil Cooler Kit XA 17 40 Goodridge Brake Hose Set XA 18 42 5th Point Seat Harness Kit XA 19 42 Rear Racelight Conversion Kit XA 20 43 Tonneau Cover XA 21 44 340R Exchange 190 bhp ECM XA 22 46 340R Tach Timer Level 1 XA 23 48 340R Competition Roll Over Bar 24 50 SS 52 772222222222 ES EES MANA NX Page 1 I Lotus Service Notes Section XA INT Lotus Cars is marketing a range of performance products for the Elise aimed primarily at competition and or track use of the vehicle Some of the kits may be used alone but others may be recommended for use only in conjunction with other complimentary kits Using the car on the public highway with competiton parts fitted may contravene emission and or noise regulations and invalidate insurance cover In addition the specification will be compromised in terms of comfort and refinement and demand increased maintenance and service In most cases
599. tion MN ENGINE MANAGEMENT SYSTEM FUSEBOX BATTERY gt IGNITION START DROP OUT D 1GNITION UNFUSED gt IGNITION FUSED J gt ALARM LUCAS 10 INSTRUMENT PACK ITACHOMETER SEE SHEET 10 DIAGNOSTIC CONNECTOR 3 08021 THROTTLE 1 2 SENSOR COOLANT TEMP ciel SENSOR INLET AIR OXYGEN SENSOR RELAY MAIN RELAY c3 c CANISTER PURGE VAL VE 5 LGS wU uP INJECTOR 3 INJECTOR 4 2 N CRANK SENSOR SENSOR 3 STUD BMM CHASSIS REAR SHEET 3 Section MN Lotus Service Notes e 8 OTU a ALARM amp IMMOBILISER LUCAS BATTERY FUSEBOX FUSEBOX IGNITION START DROP OUT 5 IGNITION UNFUSEO D IGNITION FUSEDI Av 7138 NAOH wei d 9 Q Er o uJ ROTER 5 8 fia Qe 2 amp Di ou SE ER e nos 5 STI Q uy w s ae Su a lt BEE ve x Vi gT le D in n 6 6 5 d d D lt os 9 ONI NYYM uv Ww X X o 2 LNINWNYISNI 1 00 S y2 5 2 Sd y DIAGNOSTIC 0802 CONNECTOR gt Sis E 8 9 5 I ES
600. tion MN Lotus Service Notes Section MN Buzzer sounds NO e Set up is okay f If adjustment is required remove the two circular plastic pieces holding the unit together and separate the two halves of the case Turn the adjuster screw top left hand corner as required and repeat the test Note If the sensor detects an intrusion during the first 15 seconds after alarm arming the inhibition period continues until 15 seconds elapses without the unit detecting an intrusion Subsequent intrusions will not be detected for 4 seconds after the buzzer sounds 5 Battery Back Up Siren Test a Disarm the system before disconnecting the negative battery cable Alarm triggered b Turn the siren off with the alarm override key c Reconnect the battery and turn the siren back on siren will sound d Disarm the system with the transmitter red button press twice for 1 full second each time 6 Passive Immobilisation a Disarm the system b Start the engine and then turn off ignition Wait for 60 seconds Two short flashes and buzzes YES Correct microwave C Try to start engine adjustment Engine immobilised YES Adjustment d Press once the transmitter red button e Try to start the engine Engine starts YES too high 7 Emergency Override Key a Arm the system and wait for 40 seconds b Open the passenger door Alarm triggered YES 1206 Turn off the siren with the override key d Try
601. tion supply b Starter solenoid c Fuel pump injectors The main alarm system fuse is located in an individual fuse holder near the battery Page 26 E Lotus Service Notes 340R Each headlamp cluster contains a centrally mounted dip beam headlamp side marker lamp unit a top mounted turn indicator lamp and an unlit lens at the bottom corner For access to the headlamp cluster bulbs an access panel is provided in the topshell above the front suspension secured by three socket head fasten ers Dip Beam Bulb Remove the protective cover from the back of the lamp and pull off the spade connector from the bulb Unhook the two arms of the spring clip and withdraw the bulb Note Do not touch the halogen bulb glass envelope with the fingers as the greasy deposit left behind will greatly reduce bulb life Use a paper tissue to handle the bulb Fit the new bulb into the lamp with the indexing feature defining the orientation and retain with the spring clip Connect the blue and yellow cable to the bulb terminal refit the protective cover and retain the cover with the wire spring Turn indicator Cover spring lamp bulb clip Side marker lamp bulb Protective cover Bulb retaining Headlamp clip bulb Note that the protective cover must also be removed for access to the headlamp alignment adjusters Side Marker Lamp Bulb Remove the protective cover from the back of the headlamp and pull the bulb holder downwards and out from its housing
602. tment The tank must be removed from the chassis to allow replacement of the fuel pump gauge sender unit assembly To Remove Fuel Tank 1 Remove the left hand seat and from the left hand rear corner of the cabin remove the access panel the top of the chassis rear crossmember for access to the fuel pump connections 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 LH 3 Page 5 EG Lotus Service Notes Section LH Fuel pump access panel Squeeze release tabs Release the feed and return pipes from the fuel pump by squeezing together the release tabs on the push fit connectors and withdrawing from the spigots Unplug the electrical connector from the P pump assembly 2 If necessary syphon fuel from the tank to reduce the weight before removal 3 Remove the RH rear wheel and wheelarch liner and carefully peel back the cabin bulkhead sound barrier mat to provide access to the filler hose connec tions Release the filler hose and filler breather hose from the tank spigots and cap both orifices to prevent debris in gress and reduce the fire hazard Sound barrier mat Fuel filler hose Filler breather hose Page 6 Lotus Service Notes Section LH If fitted remove the engine bay undertray diffuser Dis
603. tom boit to 5 Nm ENGINE zess OIL PUMP Remove 1 Remove and discard camshaft timing belt 2 Remove crankshaft timing gear 12M1765 3 Noting fitted position of M6 x 20 bolt A remove and discard 9 bolts securing oil pump to cylinder block 12M1766 4 Remove oil pump assembly NOTE Dowel located 5 Remove and discard oil pump gasket 6 Remove and discard crankshaft front oil seal OVERHAUL 15 ENGINE Inspection 12M 1767 12M 1768 c 1 Remove 2 screws and cover plate 2 Remove and discard cover plate seal CAUTION Two types of oil pump have been fitted The early type oil pumps fitted up to Engine No 820000 can be identified by having either a plain 6 mm diameter oil feed hole or an 8 mm diameter oil feed hole with a 6 mm counterbore in illustration Later type oil pumps fitted from Engine No 820000 all have a 12 mm diameter oil feed hole with an 8 mm diameter offset counterbore B in illustration Later type oil pumps may be fitted as replacements to all engines but early type pumps may not be fitted to engines from Engine No 820000 4 Remove all traces of Loctite from cover plate securing screws and tapped holes in oil pump body ensure screw holes are clean and dry 3 Check rotor clearances a Outer rotor to housing 0 28 0 36 mm b Inner rotor tip 0 05 0 13 mm c Rotor end float 0 02 0 06 mm Renew pump assembly if hous
604. top edge should make light contact with the soft top material If necessary slacken the eccentric adjuster on the toothed sector and the reaction channel to the door shell Then If no upstop L brackets are fitted on the door beam Overall glass height is controlled by the eccentric stop and fore aft alignment height by the position of the reaction channel To raise the front edge of the glass reaction channel in the door Check that the glass slides easily throughout its range amending the angle of the reaction channel if necessary If upstop L brackets are fitted on the door beam Check the overlap of the rear upstop brackets and if necessary amend the shimpack between L bracket and door beam to achieve an overlap of 4 5 mm Correct the glass top edge alignment and height by adjusting the position of the two upstop brackets on the beam Tighten the reaction channel fixings and check that the glass slides easily throughout its range amending the angle of the reaction channel if necessary With the glass fully raised set the eccentric stop to protect the L brackets from being overloaded by winder operation 4 5 mm overlap Door glass 1 5 mm spacer shim Window lift channel as required Rubber sleeve Door beam Buffer edge strip M Adjust to set glass height 1998 01 SE Lotus Service Notes Section BN Blank page SP 1998 01 Lotus Service Notes Section To repl
605. tor a receiver drier unit mounted on the right hand side of the radiator duct a thermostatic expansion valve fitted at the inlet connection to the evaporator an evaporator unit cooler fitted in the chassis well ahead of the cabin footwell Closed Circuit The closed refrigerant circuit should not be opened unless absolutely necessary and only then using appropriate refrigeratant recovery equipment Never allow the refrigerant to vent to atmosphere Refer to sub section PH 5 Failure to observe these precautions may result in personal injury Service ports Condenser Connector Expansion blocks Valve Compressor Connector blocks Refrigerant pipes along sill High pressure Evaporator safety valve Receiver s drier Compressor When the engine is running and the refrigeration controls demand it the electromagnetic clutch incorpo rated 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 exces sively high temperature is detected In order to avoid engine
606. tor withdrawn from the hinge bracket The rotor bushes and or bearings may then be with drawn from the hinge bracket On re assem bly note that the bearings and bushes assembled dry from above and below the up the front of the hinge bracket is designed to Rotor bush 1 engage around the profiled edge of the door BRA V 72227 1 and lower housings respectively and the Stator bracket NZ cap head screws tightened to 45 Nm Insert m t 4 the rubber bungs into the bush ends to inhibit Cap head screw Ch NA dirt ingress and corrosion N NY Hinge bracket SS N fixings BN 8 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 bonded to the inside of the shell and also contains the window front guide channel which is captive within the shell after the inner and outer door mouldings have been bonded together during manufacture 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 a
607. tor to align drive with crankshaft 6 Fit oil seal protector sleeve from seal kit over crankshaft end c NOTE This will assist in locating oil pump AN inner rotor 12M1769 7 Fit oil pump fit new Patchlok bolts M6 x 20 bolt at position 3 Tighten in sequence shown to 10 Nm 18 OVERHAUL 18G 1587 12M3596 8 Ensure oil seal protector sleeve is located over end of crankshaft 9 Position new crankshaft front oil seal on crankshaft against oil pump housing Drift seal into position using tool 18G 1587 CAUTION Oil seal must be fitted dry A 10 Remove tool 18G 1587 and oil seal protector sleeve 11 Clean crankshaft timing gear 12 Fit crankshaft timing gear 13 Fit and adjust a new camshaft timing belt ENGINE Keess COOLANT PUMP Remove 1 Remove and discard camshaft timing belt 2 Remove thermostat and housing M124980 3 Hear cover fitted Remove screw securing timing belt rear cover to coolant pump 4 Noting their fitted position remove bolts and pillar bolt securing coolant pump NOTE 2 pillar bolts are fitted to some engines 5 Release coolant pump from 2 dowels and rear cover Remove coolant pump Remove and discard O ring from pump N O Inspection 8RM 3473 1 Check for movement of pump spindle in bearing and for coolant leakage from seal Refit 1 Clean pump mating face and dowels 2 Fit new O ring to coolant pump
608. tor valve Eat Inlet tracts Fuel pressure regulator Locking solenoid valve Resonator valve actuator Charging solenoid valve Page 13 The flap capsule is vented to at mosphere and the flap valve is sprung open Inlet manifold sealed by the lock ing capsule third Cl 9 Fl valve closed Charging solenoid is energised Flap capsule is connected to mani fold vacuum flap valve is closed c Cruising oraccelerating at 30 mph n j r B lenoid Within two seconds of condition b occuring the vacuum locking sole noid is also energised and seals the vacuum in the flap capsule This is necessary in order to prevent loss of manifold vacuum during wide throttle acceleration resulting in insufficient vacuum at the flap capsule to maintain flap closure When the conditions required for intake resonance suppression no longer apply both solenoid valves are de en ergised and the flap valve is opened Vacuum Vacuum locking charging solenoid solenoid vacuum flap capsule Locking Charging solenold solenoid ON OFF Manifold FC vacuum flap capsule Locking Charging solenoid solenoid ON Manifold R vacuum To flap capsule Page 14 CS Lotus Service Notes 340R Air Cleaner The Elise 340R uses two identical Pipercross conical foam air cleaner elements contained within the air intake trunking a primary filter mounted at the inlet end of t
609. try 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 tank of fuel Ride height for geometry check front 140 mm below front end of chassis siderail rear 140 mm below rear end of chassis siderail Alignment 1 2 mm toe in each side 0 2 mm 0 0 18 toe in each side 0 03 0 Max difference side side 0 2 mm 0 03 Camber 1 8 0 2 Max difference side side 0 2 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 wh
610. tted pistons will contact the valves 4 Disconnect ht lead and plug tube from No 4 spark plug 5 Remove 2 bolts securing front coil to camshaft cover 6 Carefully raise coil until plug tube is disconnected from No 1 spark plug disconnect multiplug from coil 7 Disconnect ht lead and plug tube from No 2 Spark plug 8 Remove 2 bolts securing rear coil to camshaft cover 9 Carefully raise coil until plug tube is disconnected from No 3 spark plug 10 Disconnect multiplug from coil 2 Noting that shortest screw is fitted in centre of 11 Release hamess from clips Spark plug cover remove 3 screws securing cover to camshaft cover 3 Remove spark plug cover OVERHAUL 29 ENGINE All cylinder heads 17 Remove any debris from spark plug recesses remove 4 spark plugs M124963 M124939 18 Progressively slacken then remove 15 bolts securing camshaft cover 19 Remove camshaft cover remove and discard 12 Remove bolt securing camshaft sensor to gasket camshaft cover withdraw sensor 20 Check and record crankshaft end float 13 Remove and discard O ring 14 Release hamess from clip 15 Position harness aside 0740 16 M12 4978 21 Using sequence shown progressively slacken cylinder head bolts 1 to 6 16 Remove 2 bolts securing multipiug bracket to NOTE It will be necessary to carry out the camshaft carrier remove bracket following operations in order to remove th
611. tter key loss or failure Code wiped transmitters may be subsequently re programmed by the owner see later The following instructions for use are based on those provided in the Owner s Handbook Upgraded Vehicle Security Alarm if fitted In order to provide an exceptional level of theft and vandal protection the Lotus Elise may be factory fitted with a vehicle security alarm incorporating a Cobra 6422 system Features include Ingress protection using sensing switches on both doors front bonnet and engine lid Selectable cockpit intrusion sensing using a hyperfrequency radar sensor Automatic passive engine immobilisation to prevent the engine from being started Self powered siren to maintain protection if the vehicle power supply is interrupted Dynamic coding of the transmitter keys Each time the transmitters are used the operating frequency is randomly changed to guard against the possibility of code copying Transmitter Keys Two transmitter keys are provided with the car together with two electronic touch keys The transmitter key is used to arm and disarm the alarm and to deselect the intrusion sensor The touch key is provided as a safety back up in case of transmitter key failure e g flat battery and should be kept separate i e not on the same keyring but readily available Note that misunderstood use of the touch key can result in the transmitter key codes being wiped see later Touch key Transmitter key
612. ty during the cold running and warm up phase The Engine Coolant Tempera ture ECT sensor supplies this signal which is also used by the ECM to control the radiator cooling fan The fan is switched on at a rising coolant temperature of 102 C and switched off on falling temperature at 96 C Note that during a 15 minute period following ignition switch off the cooling fan will operate if coolant tempera ture rises above 112 C switching off again at 106 C This feature helps prevent heat soak boiling The sensor is a thermistor a resistor which changes value with temperature mounted in the outlet junction pipe at the flywheel end front side of the engine Note that the ECT sensor is mounted horizontally and should not be confused with the water temperature gauge sender which is fitted in the same pipe but vertically from below Low coolant temperature produces a high resistance whereas high temperature causes low resistance At normal running temperature the resistance will be approximately 300 400 ohms Engine Coolant Temperature ECT sensor Coolant temperature gauge sender 20204 If the ECM receives signal voltage outside of the acceptable range a default setting equating to 60 C will be substituted and the cooling fan energised To replace the sensor disconnect the harness plug and position a container to catch the escaping cool ant when the sensor is removed Unscrew the sensor from the junction pipe Clean the thr
613. ubstituted and will be displayed on the Lotus Check scanner tool in Live Data Sensor faults may cause several symptoms including poor starting fast idle speed poor fuel consumption and cooling fans running continuously 200 7 n1 Page 11 Rer Lotus Service Notes Section EMN The intake air temperature IAT sensor is fitted into the inlet manifold tract of no 4 cylinder and is a transducer with a negative temperature coefficient such that its electrical resistance reduces with increasing temperature Using this signal in conjunction with that from the MAP sensor the ECM is able to determine the air consumption of the engine and adjust the injector pulse width accordingly for correct fuelling Low air temperature results in denser air requiring more fuel High air temperatures are also used by the ECM to retard the ignition timing and avoid knock f fife OUS EON SS amp di se To replace the sensor unplug the electrical connector and unscrew the sensor from the manifold Before fitting a sensor clean the threads and mating face and screw into the manifold tightening to 7Nm Mate the harness plug 2000 01 ie Lotus Service Notes Section EMN The throttle position TP sensor is a potentiometer fitted directly to the end of the throttle spindle and provides the ECM with information on both throttle opening and rate of change of thrott
614. uide lugs with two machined grooves that form a platform for a lock plate The inner face of the lock plate is angled approximately at 45 with two machined flanges either side of the lock plate which are positioned in machined grooves in the guide lugs A return spring which biases the lock plate against the stop surface extends along the step at the front of the lock plate with the two free ends of the spring held in position by two Taptite screws either side of the shift piece A lug on the 3rd 4th selector fork has a machined face at an angle of 45 which acts as a ramp when in contact with the angled face of the lock plate 1st 2nd selector shaft has a machined abutment surface located below the detent grooves the abutment surface being the area of contact for the lock plate 8 DESCRIPTION AND OPERATION REVISED 12 97 OPERATION REVERSE BRAKE When selecting reverse gear the 5th reverse shift piece 1 moves upwards and the angled face of the lock plate 3 contacts the ramp of 3rd 4th selector fork 2 The upward movement carries the lock plate 3 outwards until it contacts the abutment 4 on 151 2 selector shaft From this point continued upward movement of the 5th reverse shift piece 1 causes the lock plate 3 to move the 3rd 4th selector and synchro sleeve 5 towards 4th gear The movement of the 3rd 4th synchro sleeve 5 is sufficient to restrain the input shaft 6 thus permitting smooth engagement o
615. ular component or vehicle Rover Dealers are not agents of Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation Gearbox identification This overhaul manual is applicable to PG1 gearboxes having the following Serial No prefixes C4BP R4A0 C4BS R4DT C6BN S4DTU 6 S4EM CeBS SAFTU SeBSU S6AO CeDTUT S6BN CeDTUTH S6BNU C6DUTH S6BS C6FTUT S7EMU K4BS V4DT K4BX VeBS W4DT K6BN W4DTUT K6BS Y4AO K7BSUT K7BX 5 5 2 INTRODUCTION REVISED 12 97 MANUAL GEARBOX CONTENTS Page DESCRIPTION AND OPERATION GEARBOX COMPONENTS 3 SECTIONED VIEW OF GEARBOX 4 4 44 4 0 4 5 DESCRIPTION TORSEN DIFFERENTIAL 2 24 4 2 1 5 OPERATION EE 5 OPERATION TORSEN DIFFERENTIAL 00 6 DESCRIPTION REVERSE 2 2 2 4 20 8 OPERATION REVERSE BRAKE 2 2 24 4 2 9 OVERHAUL GEARBOX 2 2 222 2 1 COMPONENT DISMANTLING 0 8 inp t SHAN 22 cciseseccsacsasecsedelesaseocaseseseatbucscsecbinsatbageodegdebesdevedsageve yes Ug en Ree Yea noes 8 Output Stat 8 Synchro assemblies Pede Pee eer
616. uld be switched off as soon as the windscreen is cleared A 15 minute timer automatically turns off the circuit after this period and an off default will apply when the ignition is switched off Hazard Warning Lamps Switch A push button switch for the hazard warning lamps is located between the instruments with the red tell tale in the switch button back lit when the sidelamps are switched on to help locate the switch The switch is operative at all times and when pressed flashes all the turn indicator lamps and the switch tell tale in unison This facility should be used to warn other traffic of a road hazard possibly including the prescence of the vehicle itself Use of the hazard warning lamps may be subject to local traffic laws with which drivers should familiarise themselves Column Lever Switches The steering column lever switches for the turn indicators headlamp beam dip flash and windscreen wipe wash are as used on the standard Elise Auxiliary P Two auxiliary power sockets are provided at the rear of the cockpit centre divide to ac commodate heated motorcycle type cloth ing or similar equipment The sockets are fitted with protective blanking plugs and are powered only when the engine is running at over 2 000 rpm at which time a maximum current of 15 amps may be drawn from each socket Auxiliary power sockets The fuel pump cut off safety inertia switch INERTIA is fixed to the chassis at the left hand
617. unit into the tank ensuring that the O ring is positioned correctly and align the pipe spigots on the end plate with the tank main axis pointing to the left Tighten the clamp ring nuts to 2 6 Nm LH 7 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 adsorbs 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 Page 10 Lotus Service Notes Section LH a port in the throttle body such that fresh air is drawn through the canister to purge the charcoal of its adsorbed fuel with the resultant gas then consumed by the engine in the normal combustion process Charcoal Canister This is mounted at the left hand front corner of the engine bay via a tapered lug on the canister and corresponding bracket on the bulkhead Charcoal canister Solenoid valve Tapered mounting bracket Canister purge line Canister vent Breather from tank Fuel vapour from the top of the fuel tank filler neck is routed via a roll over valve to prevent fuel spillage if the car is inverted mounted on a bracket integral with the filler neck to the canister port labelled tank A central tube in the canister connects this port to the underside of the charcoal bed below which is a reservoir to collect any liquid fuel
618. unsnap the select cable from the lever ball Pull off the spring clip retaining the cable outer to the abutment bracket and release the cable from the bracket At the rear end prise the cable off the lever pull off the outer cable spring clip and release from the abutment bracket Release cable ties and clips as necessary to allow the cable to be withdrawn noting the routing past the park brake lever Refit in reverse order to removal paying particular attention to the routing through or alongside the park lever and gear lever mounting brackets Check the cable adjustments as detailed above Gearlever Mounting Bracket The gear lever mounting bracket is secured to the cabin floor by four M8 bolts the rearmost of which also fixes the front of the parking brake lever bracket Note that alloy spacers are used on the front three fixing points between bracket and floor The whole assembly is offset towards the passenger side of the car with alternative fixing holes provided either in the mounting bracket or in the cabin floor FH 3 LUBRICATION Level filler plug The PG1 transmission is filled for life with Texaco MTF94 fully synthetic lubricant and requires no periodic renewal If there are any signs of leakage the source should be identified and appropriate action taken to rec tify the fault A filler level plug is provided on the left hand side of the the final drive housing and with the car parked on a level surface the oil
619. upport bracket 1 M5 5 6 Nm yes 5 Pipes to connector blocks 4 M6 7 9 Nm yes 6 Elbow pipe condenser inlet 2 3 4 16 UNF 25 30 Nm n a 7 Condenser outlet pipe to condenser and receiver drier 2 5 8 18 UNF 20 25 Nm n a 8 Trinary switch to receiver drier 1 3 6 24 UNF 10 13 Nm n a 9 Outlet pipe to receiver drier 1 5 8 18 UNF 20 25 Nm n a 10 Clamp plate pipes to exp valve 1 M6 7 9 Nm yes 11 Clamp plate exp valve to evaporator 2 M5 5 6 Nm no All O rings and connector union threads should be coated with refrigerant oil Sanden SP20 or Seiko SK20 prior to assembly Gloves should be worn when handling refrigeration oil 2000 04 E Lotus Service Notes Section PH REFRIGERANT PIPEWORK TORQUE CHART 2000 04 Page 15 Lotus Service Notes Section PH 8 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 spec
620. ured to the passenger floor crossmember using threaded inserts A release handle is mounted in the fascia and externally on the front wing Extinguisher nozzles are mounted in the cockpit and at both sides of the engine bay Pay close attention to any fitting instructions supplied with the kit and check any specific requirements of competition events Page 15 Section XA Lotus Service Notes 16 Lotus Service Notes Section XA 7 UNIBALL TOE LINK 111001275 For competition use especially if slick tyres are to be used with the associated increase in suspension loadings it is recommended to replace the rear suspension toe control links with uniball type links complete with brackets which support both ends of the pivot bolts and provides additional strength to the chassis and hub carrier fixings This kit is designed to be used in conjunction with the Road Spring amp Damper SetA111C01388 using the lowered ride height 100 110mm as detailed in sub section XA 8 The correct bump steer character istic is not attainable at the standard ride height At the inboard chassis end of the link a steel bracket supports the rear end of the pivot bolt and requires that the chassis be drilled to accept the four M6 screws fixing each of the brackets Locate the bracket using the pivot bolt before marking up the four fixing hole positions on the chassis rear subframe At the outboard end of the link a mille
621. urning of the mandrel If the diaphragm spring fingers begin to pinch the mandrel and a drag on its turn ing is felt remove the tool Finally tighten the cover fixing screws to 25 Nm Centralising mandrel 700071483 11 Lotus Service Notes Section QF 22 Refit the transmission to the engine engaging the gearbox input shaft into the friction plate splines and locating the clutch housing onto the engine mating face dowels 23 Continue re assembly in the reverse order to disassembly with the following notes Use new circlips on the spigots of the inboard C V joints and check that the driveshafts are fully inserted into the transmission by pulling on the inboard joint bodies Use a new O ring on the speedo drive cable and lubricate on assembly Renew the two topmost bell housing to engine patchlock bolts or apply a suitable threadlocking com pound if re using original bolts Use special tool 700071390 to protect the output shaft seals during driveshaft refitment see sub section FH 5 Engine Transmission Fixings viewed onto LH end M12 Patchlock bolts 75 90 Nm M12 engine to housing 75 90 Nm 120 M12 nut amp bolt 75 90 Nm M10 bolt housing M10 bolt sump to to sump 40 50 Nm housing 40 50 Nm 1998 02 E Lotus Service Notes Section XA MOTOR SPORT SECTION XA ELISE Sub Section Page introduction XA 1 2 190 VHPD Engine XA 2 2 Competi
622. us Service Notes Section Horn slip M6 x 20 capscrew ring carrier A082W7041F x 16 screw A918W7120F Horn earth Steering wheel Spigot hub extension Steering wheel spacer Alignment Splined hub Hub spacer Key lock barrel Horn contact Locking adaptor ring Horn push button Page 32 6 Il Lotus Service Notes Section XA 14 STAGE 2 135 BHP ENGINE TUNE UP KIT 111 62155 This kit comprises a reworked cylinder head assembly and cast alloy intake manifold and plenum It is designed to be used in conjunction with the competition silencer A111S0037S and for track use with the cata lyst replacement pipe A111S0048S Cars fitted with an aluminium boot bulkhead will also require this item changing for a reprofiled version supplied in the kit A modified engine cover lid in composite material is available to clear the new intake plenum but itis possible to trim modify the existing aluminium lid to fit A running change made to the cam belt tensioner mechanism on the Rover K16 engine requires that cylinder heads with different belt tensioner machining details are used On engines with serial numbers prior to 153993 kit A111E62158S should be used with later engines using B111E6215S Contents of Stage 2 Kit Qty Cylinder Head Assembly 1 comprising Cylinder head 1 Cam cover 1 Cam cover bolts 15 Tappets 16 Valve spring cap 16 Valve stem seal 16 Valve spring 16 Modified inlet
623. use RTV sealant to retain O ring BRM 0055 3 Fit coolant pump to cylinder block fit bolts and pillar bolt s and tighten in sequence shown to 10 Nm 4 Hear cover fitted Fit timing belt rear cover securing screw tighten to 9 Nm 5 Fit thermostat and housing 6 Fit and adjust a new camshaft timing OVERHAUL 19 ENGINE THERMOSTAT Remove 12M0558 1 Remove 2 bolts securing coolant rail to cylinder block release rail from thermostat cover 2 Remove bolt securing thermostat housing and dipstick tube to cylinder block 3 Withdraw thermostat housing from coolant pump 4 12M0559 4 Remove and discard O rings from thermostat housing and cover 5 Remove 3 bolts and remove cover from thermostat housing Withdraw thermostat from housing Remove and discard seal from thermostat NO inspection 1 Test thermostat using thermostat test equipment renew thermostat if necessary 2 Thermostat open 88 C Starts to open 85 to 91 C Fully open 100 C Refit 1 Clean thermostat housing cover and sealing faces 2 Lubricate new O rings with silicone grease and fit to thermostat housing and cover 3 Fit anew seal to thermostat 4 Align and fit thermostat to shoulder in thermostat housing 5 Fit cover to thermostat housing fit and tighten bolts to 8 Nm CAUTION Torque figure must not be AN exceeded 6 Fit thermostat housing to coolant pump align
624. use only the specified materials The surface preparation and cleaning and priming operations 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 082 6150 Primer Betaprime 5001 Lotus part A100B6009V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Unpainted or painted composite Cleaner Betaclean 3900 Lotus part no A100B6008V Primer Betaprime 5404 Lotus part no A082B6337V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Zinc plated and passivated steel Cleaner Beatclean 3900 Lotus part no A100B6008V Primer Betaprime VP 01706 A B Lotus part no A100B6070V Adhesive Betaseal 1701 Lotus part no A082B6281F Glass Cleaner Betawipe VP 04604 Lotus part no A082B6150V Primer Betaprime 5001 Lotus part no A100B6009V Adhesive Betaseal 1701 Lotus part no A082B6281F or Betamate E2400 Lotus part no A082B8415V Uncoated Lexan Perspex Cleaner Abrasion amp dry wipe Primer Betaprime 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
625. ut lock rings to allow setting of ride height and corner weighting Also included for use on cars prior to their introduction at VIN W 3580 approx are stronger top rear damper mounting brackets with repositioned 10mm higher damper holes together with load spreading clamp plates to fix the brackets to the chassis The pair of steering rack positioning plates are provided in order to maintain the desired bump steer characteristic if the lowered ride height is used Additional parts recommended to be fitted with this kit are Front hub bearing clamp bolt set 111 01375 applicable to cars prior to VIN V 1830 Sept 97 Rear Uniball toe link kit 111001275 Adjustable uprated front anti roll bar 111 01345 The springs dampers and rear top damper mounting brackets with spreader plates are direct replace ments for the standard parts The dual rate front springs are fitted with the close coiled end lowermost The recommended mid laden ride height 2 people 1 2 tank fuel to be used with these springs and road tyres is as follows Front 100 mm below front end of chassis siderail standard setting 140 mm Rear 110 mm below rear end of chassis siderail standard setting 140 mm At the lowered ride height the steering rack should be repositioned by removing the rack fixings from the front of the footwells drilling out the pop rivets retaining the standard 5 notch rack height setting plates and fitting new 10 notch plates A
626. utton on the transmitter key the tell tale will extinguish and the engine may be started If the key is already turned to the ignition position Il either of the two buttons on the transmitter key may be pressed to mobilise Note that for only the German market if the ignition is not switched on within 4 minutes 15 seconds of the alarm being disarmed immobilisation will be automatically activated To Arm the Alarm Remove the ignition key close and lock both doors and press once the transmitter key button embossed with the padlock symbol This command will be acknowledged by The hazard lamps flashing three times The Alarm tell tale in the instrument pack flashing rapidly for 10 seconds the arming period then flashing once per second To Disarm the Alarm Press once the transmitter key smooth button This command will be acknowledged by a single flash of the hazard lamps and the alarm tell tale going out The same disarming command applies if the alarm has been triggered and the horn is sounding Note that some variations to the alarm operation may apply in certain territories according to local regulations Transmitter Battery Replacement Each of the transmitter keys is powered by a Panasonic CR2032 battery With normal use these should last between 6 and 9 months To ensure continuity of trouble free operation it is recommended to replace both batteries at 6 monthly intervals Page 2 Lotus Service N
627. vel joint plinth to hub carrier 45 Lower swivel joint plinth to hub carrier 45 Toe link outer ball joint to hub carrier 45 Toe link ball joint lock nuts 78 Damper to lower wishbone 45 Damper to chassis 45 Caliper mounting bracket to hub carrier early tapped into carrier 45 Caliper mounting bracket to hub carrier later through bolted 62 Brake caliper to mounting bracket upper M10 45 50 lower M8 26 30 Rear hub nut 220 4 REAR TOE LINK FIXINGS The inboard end of the rear toe link shares its fixing to the chassis with the lower wishbone rear pivot bush The outboard end of the link is fixed to a rearward extension of the hub carrier with a conical spacer and shim washers providing a means of adjusting the amount of toe in produced with suspension travel referred to as the bump steer characteristic cars built prior to December 98 the ball pins of the toe link joints incorporate female M10 threads into which are fitted M10 bolts the length of which are critical to ensure adequate thread engagement without danger of bottoming out in the joint with the length of the outboard bolt dependent on the bump steer shim pack Cars built from December 98 onwards use toe link ball joints with integral studs secured to the chassis and hub carrier with M10 Nyloc nuts The outboard end conical spacer and bump steer shim washers differ for the integral stud type joints and should not be mixed with the earlier components Servi
628. voir by pulling upwards from its mounting bracket To remove the battery disconnect both battery cables see below and pull off the breather pipe from the outboard end of the battery Release the three screws securing the battery clamp bracket to the chassis remove the clamp bracket and tilt the battery to release the lower edge from its retain ing channel Lift out the battery from its well taking suitable precautions with regard to the battery weight and difficult access Refit the battery with its terminals towards the front by reversing the above procedure Ensure that the breather pipe is connected and routed correctly or corrosion damage to the chassis is likely to occur Recon nect the battery cables as detailed below Battery vent Hole at base of battery well Pipe runs through lower wishbone chassis channel Disconnecting the Battery If the battery is to be disconnected the following precautions should be taken i If the car is fitted with the Cobra alarm in order to avoid triggering the alarm when the battery is discon nected first turn off the alarm system using the special override key Fit the key into the switch on the Page 18 E Lotus Service Notes Section MN siren housing in the top of the passsenger footwell and turn counterclockwise ii 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 startin
629. vot bolt and fit the bracing strut corner plate over the end of the pivot bolt into the corner of the footwell Mark the four fixing hole positions in the corner bracket against the chassis before removing the bracket and drilling the marked holes 9 mm diameter 5 For access to the corner plate fixings inside the chassis side rail it is necessary to cut an access aperture in the underside of the chassis rail With a centre marked as shown in the diagram use a hole cutter or similar tool to cut a 35mm diameter hole and remove the sharp edge Page 11 Lotus Service Notes Section XA 6 Fitthe corner plate fixings using the reinforcing plate on the underside of the floor and tighten the fixings in the following order Wishbone pivot bolt 45 Nm at normal ride height 8 fixings 22 Nm 7 Fit the access grommet in the chassis side rail underside 8 Slide the U end spigot onto the bracing strut and engage the bracing strut front end into the corner plate at the same time as positioning the U bracket over the roll hoop and frame apex Fit and tighten the bolt clamping the U bracket to the A frame 9 Mark the position of the top and bottom holes in the U bracket and corner plate tubes against the strut spigots Release the U bracket from the A frame and hoop and withdraw the bracing strut Drill the marked holes in each spigot to 9 mm diameter Refit the bracing strut and U bracket and insert the M8 X 50 bolts
630. w throttle cable A111J0140S to the engine connecting to the linkage between the two throttle bodies and route as previously to the pedal box 11 At the pedal box check the specification of U bracket attaching the throttle linkage to the pedal The later type introduced January 98 bracket must be fitted which is both thicker and wider Check also that the bracket is correctly assembled and hooked through the pedal ex trusion U bracket Throttle pedal Page 5 Lotus Service Notes Section XA Old type 1 6 mm thick 10 mm wide Later type 2 0 mm thick 15 mm wide C111J0046F If necessary rivet the later type bracket to the pedal using a 3 16 dia 1 2 reach pop rivet 12 Also atthe pedal box check the specification of the throttle linkage relay lever The later type B111J0045F introduced February 98 must be fitted which is notched to allow for clearance with the mounting plate fixing with the greater required lever travel Alternatively the existing lever may be modified as shown below Fit notched side to rear driver Radius 12 5mm 20mm Adjust the cable at the throttle body abutment to allow full throttle to be attained If necessary adjust the pedal upstop and pedal pullrod length Ensure that the pedal downstop is set to protect the cable from strain at full throttle 13 The engine is supplied with a new ECM together with a matched security 5AS module If the car is to be used in
631. ways replace the screw or retreat with Loctite 242 The rotor arm incorporates a sup pressor and has a resistance value of 1 25 kohms The distributor cap is retained by two screws and is pro tected from oil contamination from camshaft oil seal leakage by a deflector plate Note that there is no requirement or provision made for positional adjustment of the distributor Inlet camshaft Rotor Distributor arm cap Oil deflector plate Rotor arm fixing screw Distributor cap fixing screw These engines use a Distributorless Ignition System DIS employing a pair of double ended coils mounted on the RH side of the cylinder block Each coil supplies two spark plugs simultaneously one to a cylinder on its compression stroke and one on its exhaust stroke the latter being wasted such that the system is sometimes described as wasted spark Coil one supplies spark plugs 1 amp 4 and coil two supplies plugs 2 amp 3 Each double ended coil contains a primary winding connected in series with the supply and the ECM and an isolated secondary winding connected in series with two spark plugs It is important to note that there is no connection between the primary and secondary windings The coils are triggered by the ECM which switches off the primary voltage and induces a high tension current to produce a spark in the spark plug connected to each end of the secondary winding The direction in which the secondary winding is wound determ
632. 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 pre vent 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 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 pre vented 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 Recommended Pipework Tightening Torques Ref Description Qty Thread Torque Washer 1 Compressor to mounting bracket 3 M10 43 47 no 2 Belt tensioner pulley securing nut 1 M8 25 Nm as supplied 3 Pipe union to compressor 2 M8 23 27 Nm no 4 Pipe s
633. ws a Normal running Both solenoid valves off Flap valve open The flap capsule is vented to at mosphere and the flap valve is sprung open Inlet manifold sealed by the lock ing capsule b Cruising at 30 mph in second or third gear Charging solenoid on Flap valve closed Charging solenoid is energised Flap capsule is connected to manifold vacuum flap valve is closed C Cruising oraccelerating at 30 mph in second orthird gear Both solenoids on Flap valve closed Within two seconds of condition b occuring the vacuum locking sole noid is also energised and seals the vacuum in the flap capsule This is necessary in order to prevent loss of manifold vacuum during wide throttle acceleration resulting in insufficient vacuum at the flap capsule to maintain flap closure When the conditions required for intake resonance suppression no longer apply both solenoid valves are de en ergised and the flap valve is opened Vacuum Vacuum locking charging solenoid solenoid OFF ifold To flap capsule vacuum Locking solenoid Charging solenoid Manifold vacuum To flap capsule Locking solenoid Charging solenoid ON vacuum To flap capsule 215 14 2000 05 EG Lotus Service Notes Exige Ni Purge rail E225 To MAP sensor o 57 GE amp intake resonator P control system S 9 2 lt Le To charcoal ut
634. y Refer to section DE for rear suspension assembly details For coolant refilling procedure refer to section KF For transmission details and gear cable adjustment refer to section FH Torque Figures Nm RH engine mounting bracket to engine 145 RH engine mounting bracket to rubber mounting 82 RH engine rubber mounting to chassis 45 RH engine steady arm bolts 87 LH engine mounting bracket to rubber mounting 82 LH engine mounting bracket to engine 45 Lower steady arm bracket to sump 80 Lower steady arm bolts 77 Use Permabond A130 A912E7033V at sump end of arm EE 4 SPECIAL TOOLS The following engine special tools are available under Lotus part number Flywheel locking tool transmission fitted TO00T1289 Flywheel locking tool transmission removed T000T1367 Camshaft locking tool T000T1282 Crankshaft rear oil seal replacer TOOO0T1284 Valve stem oil seal remover replacer 000 1285 Cylinder liner clamps TO00T 1288 Sump alignment pins 2 off 700071290 Torx E12 cylinder head bolt socket TOO0T1366 Crankshaft Camshaft front seal replacer TOOOT1286 Camshaft holding turning tool TOOOT 1280 Engine lifting brackets T000T1283 Ng NB 45 322 242221022 UC INE P RES ORB Ee 6 SERIES ENGINE OVERHAUL MANUAL This overhaul manual is applicable to K Series engines fitted with either VVC or non VVC cylinder heads and damp cylinder liners This engine is fitted to the followin
635. y 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 unmade road environments and will reduce braking performance No skimming or re surfacing of the brake discs is permitted If the disc becomes badly scored 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 Brake disc thickness New 26 0 mm 1 02 in Service minimum 24 9 mm 0 98 in Runout New maximum 0 03 mm 0 001 in Front Disc Replacement 1 Remove the road wheel 2 Remove the two bolts securing the brake caliper to the hub carrier and withdraw the caliper from the disc Secure clear without straining the flexible hose 3 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 hu
636. y 7 is fed through the oil rail below the main bearing ladder in which drillings direct the oil to the main bearings Cross drillings in the crankshaft from No 2 and 4 main bearings carry the oil to the big end bearings A passage in the oil pump housing connects to a drilling 8 in the cylinder block to 9 in the cylinder head K8 engine Oil is fed through the cylinder head to a drilling 10 in the one piece camshaft carrier to supply oil to each hydraulic tappet and camshaft bearing k16 engine Oil is fed through the cylinder head to twin full length oilways 10 in the camshaft carrier to supply oil to each hydraulic tappet and camshaft bearing VVC engines The VVC mechanisms are lubricated by oil fed via the inlet camshafts An oil temperature switch 11 is fitted in the oil filter head for certain models In the event of engine oil temperature rising above a pre set level a waming light will iluminate on the instrument panel Crankcase ventilation A positive crankcase ventilation system is used to vent blow by gas from the crankcase to the air intake system K8 engine Crankcase gas is drawn through a gauze oil separator in the camshaft cover and passes via a hose into either the carburetter or throttle body ahead of the throttle disc K16 engine Crankcase gas is drawn through a gauze oil separator in the camshaft cover and passes via hoses into the throttle housing DESCRIPTION AND OPERATIO

Lotus Elise S1 Service Manual

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