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Lotus 2004 Eleven, Service Notes, Page: 1 / 545

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Lotus 2004 Eleven Service Notes Download Page 1

SERVICE

NOTES

 

2004 Model Year Onwards

with 1ZZ/2ZZ/1ZR Engine

Lotus Cars Ltd.  Hethel, Norwich, Norfolk, NR14 8EZ, England.

Tel: +44 (0)1953 608000  Fax: +44 (0)1953 608300  www.GroupLotus.co.uk

Summary of Contents for 2004 Eleven

Page 1: ...SERVICE NOTES 2004 Model Year Onwards with 1ZZ 2ZZ 1ZR Engine Lotus Cars Ltd Hethel Norwich Norfolk NR14 8EZ England Tel 44 0 1953 608000 Fax 44 0 1953 608300 www GroupLotus co uk ...

Page 2: ...J Toyota 1ZR repair manual see separate CD T000T1523F Engine Management EMP Transmission Lotus supplement FJ Toyota C64 C56 repair manual see separate manual E120T0327J Toyota EC60 repair manual see separate CD T000T1523F Wheels Tyres GH Steering HG Brakes JJ Engine Cooling KH Fuel System Except North America LJ North America LK Electrics MP Maintenance Lubrication OI Air Conditioning Heating Vent...

Page 3: ...tor and is prefaced by 1ZR Both V I N and engine numbers should always be quoted with any vehicle enquiries as Factory records are filed against V I N and specification change points are identified by V I N or engine number The vehicle licence plate should be disregarded in this context as it may not accurately reflect vehicle age and may also be changed during the car s life The V I N comprises 1...

Page 4: ...rack D LHD Other L South Korea E Gulf States F RHD SVA Build Type 1 Std 2 Proto Serial Number 2004 M Y 2010 M Y serial no 0359 Assembly Plant Model Vehicle Type H Hethel 2 2 Eleven Manufacturer 111 Elise Exige Check B Shah 3 Elise Identifier Code 123 2 Eleven Digit Alam 8 Exige S C C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Engine Type Restraint Model Year Chassis Body Serial A 2ZZ s c 260 c c A ...

Page 5: ...Limited edition of 50 units produced as post registration official factory conversions of 05 Exige by the Lotus Sport workshops at Hethel for U K and certain overseas territories The car is not identifiable from the VIN coding Differences compared to standard Exige include 243 bhp engine upgrade using Eaton M62 supercharger with integral by pass valve air air chargecooler and 5th fuel injector Re ...

Page 6: ...Elise Exige and 06 include Elise 111R renamed Elise R New sealed headlamp units raised LOTUS lettering on rear transom additional screen pillar seal Alpine audio improved HVAC duct ing New model Elise S uses 1ZZ FE engine producing 100 kW with variable inlet timing but fixed valve lift plastic inlet manifold revised intake snorkel revised exhaust manifold and downpipe smaller tailpipes within stan...

Page 7: ...iversary of Lotus F1 1972 World Championship victory with the type 72D Phantom black body colour with hand painted gold pinstriping Rear body spoiler black diffuser Gold laurel leaf decal on front quarters gold Elise and Type 72D decals gold raised LOTUS lettering gold black nosebadge gold fuel filler cap Gold Exige 8 split spoke wheels with Yokohama A048 tyres and sports suspen sion Black gold se...

Page 8: ...p lightweight flywheel uprated clutch Torsen LSD Variable Traction and Launch control excludes warranty 4 piston front brake callipers and enlarged front discs braided hoses Bilstein or Ohlins adjustable spring dampers stiff adjustable ARB in hard mounts hi power silver 16 spoke cast wheels A048 tyres FIA compliant battery isolator and plumbed in fire extinguisher T45 seat belt anchorage frame FIA...

Page 9: ...mited edition of 20 for U K 20 for Europe plus selected RoW territories Phantom Black with gold pin striping gold Exige S on rear Type 72 on passenger B panel Sport and Touring Packs Machined forged 5 spoke wheels in black and gold Black microfibre trim with gold stitching Build plaque with GP win Exige Scura Stealth January 2010 Limited edition of 35 cars for Europe and some RoW territories Badge...

Page 10: ...f the car and also help to keep the engine bay clean Do not run the car without the panels fitted Typical model shown others similar 3 screws to licence 1 screw each side plate plinth to grille panel b275b Diffuser panel 3 screws each side Single screw each to tank bay side to clamshell panel Undertray front edge M8 button head slots into 2 to subframe 5 screws M8 button head chassis undertray 2 t...

Page 11: ... side at a time for wheel changing lifts both wheels on one side Do not use with a four point garage lift B Beneath the front end of the right or left hand main chassis rail behind the front wheelarch Garage use with 4 point lift in conjunction with C C The engine undertray diffuser panel must first be removed Beneath the outboard end of the chassis crossmember ahead of the rear wheelarches Take c...

Page 12: ...ry 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 com plete freedom from errors or omissions or to accept liability arising from such errors or omissions but nothing herein contained ...

Page 13: ... Toyota C64 C56 repair manual see separate manual E120T0327J Toyota EC60 repair manual see separate CD T000T1523F Wheels Tyres GH Steering HG Brakes JJ Engine Cooling KH Fuel System Except North America LJ North America LK Electrics MP Circuit Diagrams non USA prior 06 MP14a Circuit Diagrams USA prior 06 MP14b Circuit Diagrams 06 Onwards MP14c Circuit Diagrams 08 Onwards MP14d Circuit Diagrams 11 ...

Page 14: ...tor and is prefaced by 1ZR Both V I N and engine numbers should always be quoted with any vehicle enquiries as Factory records are filed against V I N and specification change points are identified by V I N or engine number The vehicle licence plate should be disregarded in this context as it may not accurately reflect vehicle age and may also be changed during the car s life The V I N comprises 1...

Page 15: ...rack D LHD Other L South Korea E Gulf States F RHD SVA Build Type 1 Std 2 Proto Serial Number 2004 M Y 2010 M Y serial no 0359 Assembly Plant Model Vehicle Type H Hethel 2 2 Eleven Manufacturer 111 Elise Exige Check B Shah 3 Elise Identifier Code 123 2 Eleven Digit Alam 8 Exige S C C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Engine Type Restraint Model Year Chassis Body Serial A 2ZZ s c 260 c c A ...

Page 16: ...Limited edition of 50 units produced as post registration official factory conversions of 05 Exige by the Lotus Sport workshops at Hethel for U K and certain overseas territories The car is not identifiable from the VIN coding Differences compared to standard Exige include 243 bhp engine upgrade using Eaton M62 supercharger with integral by pass valve air air chargecooler and 5th fuel injector Re ...

Page 17: ...Elise Exige and 06 include Elise 111R renamed Elise R New sealed headlamp units raised LOTUS lettering on rear transom additional screen pillar seal Alpine audio improved HVAC duct ing New model Elise S uses 1ZZ FE engine producing 100 kW with variable inlet timing but fixed valve lift plastic inlet manifold revised intake snorkel revised exhaust manifold and downpipe smaller tailpipes within stan...

Page 18: ...iversary of Lotus F1 1972 World Championship victory with the type 72D Phantom black body colour with hand painted gold pinstriping Rear body spoiler black diffuser Gold laurel leaf decal on front quarters gold Elise and Type 72D decals gold raised LOTUS lettering gold black nosebadge gold fuel filler cap Gold Exige 8 split spoke wheels with Yokohama A048 tyres and sports suspen sion Black gold se...

Page 19: ...p lightweight flywheel uprated clutch Torsen LSD Variable Traction and Launch control excludes warranty 4 piston front brake callipers and enlarged front discs braided hoses Bilstein or Ohlins adjustable spring dampers stiff adjustable ARB in hard mounts hi power silver 16 spoke cast wheels A048 tyres FIA compliant battery isolator and plumbed in fire extinguisher T45 seat belt anchorage frame FIA...

Page 20: ...mited edition of 20 for U K 20 for Europe plus selected RoW territories Phantom Black with gold pin striping gold Exige S on rear Type 72 on passenger B panel Sport and Touring Packs Machined forged 5 spoke wheels in black and gold Black microfibre trim with gold stitching Build plaque with GP win Exige Scura Stealth January 2010 Limited edition of 35 cars for Europe and some RoW territories Badge...

Page 21: ...f the car and also help to keep the engine bay clean Do not run the car without the panels fitted Typical model shown others similar 3 screws to licence 1 screw each side plate plinth to grille panel b275b Diffuser panel 3 screws each side Single screw each to tank bay side to clamshell panel Undertray front edge M8 button head slots into 2 to subframe 5 screws M8 button head chassis undertray 2 t...

Page 22: ... side at a time for wheel changing lifts both wheels on one side Do not use with a four point garage lift B Beneath the front end of the right or left hand main chassis rail behind the front wheelarch Garage use with 4 point lift in conjunction with C C The engine undertray diffuser panel must first be removed Beneath the outboard end of the chassis crossmember ahead of the rear wheelarches Take c...

Page 23: ...us Service Notes Section TDP TECHNICAL DATA ENGINE SECTION TDP Page General 2 Cylinder Block 3 Cylinder Head 3 Valves Springs 3 Camshafts 3 Pistons 3 Connecting Rods 3 Crankshaft 3 Oil Pump 3 Coolant Thermostat 4 ...

Page 24: ... open 42 BBDC 65 BB to 30 BB close 2 ATDC 1 BT to 34 AT Compression ratio 11 5 1 10 0 1 10 7 1 Compression pressure 250 rpm new 1400 kPa 1500 kPa 1400 kPa service limit 1000 kPa Firing order 1 3 4 2 Spark plugs NGK IFR6A11 NGK BKR5EYA 11Denso 20HR11 Spark plug gap 1 1 mm 1 0 0 05 mm 1 0 1 1 mm Maximum continuous engine speed 8000 rpm 6 800 rpm 6 800 rpm Maximum transient engine speed 8500 rpm 7 00...

Page 25: ... mm service limit 0 15 mm 0 11 mm 0 17 mm PISTONS Diameter 90 to pin 12 mm from bottom edge 81 975 81 993 80 470 80 496 90 to pin 25 mm from top edge 78 925 78 935 Ring gap 110 mm from bore top std no 1 0 25 0 35 mm no 2 0 35 0 50 mm oil rail 0 15 0 40 mm max no 1 1 1 mm no 2 1 2 mm oil rail 1 1 mm 50 mm from bore top std no 1 0 20 0 30 mm no 2 0 30 0 50 mm oil rail 0 10 0 40 mm max no 1 0 50 mm n...

Page 26: ... mm service limit 0 33 mm Inner rotor tip clearance new 0 06 0 18 mm 0 08 0 16 mm service limit 0 33 mm Rotor end float new 0 03 0 08 mm 0 09 0 14 mm service limit 0 16 mm COOLANT THERMOSTAT Valve opening temperature 80 84 C Valve lift 10 mm 90 C 10 mm 82 C Header tank pressure cap 108 kPa Cap opening pressure 93 123 kPa ...

Page 27: ... Section TDQ TECHNICAL DATA VEHICLE SECTION TDQ Page Dimensions 2 Capacities 3 Wheels Tyres 3 Front Suspension 4 Rear Suspension 4 Electrical 5 Transmission 6 Clutch 6 Brakes 7 Steering 7 Fuel Consumption 7 Updated 9th June 2010 ...

Page 28: ...r 533 kg Elise S total 862 kg lightest front 328 kg incl full fuel tank rear 534 kg USA Elise total 912 kg heaviest front 344 kg incl full fuel tank rear 568 kg Elise 2011 total 876 kg lightest front 342 kg incl full fuel tank rear 534 kg non USA Exige total 875 kg front 328 kg incl full fuel tank rear 547 kg non USA Exige S total 935 kg front 355 kg incl full fuel tank rear 580 kg USA Exige total...

Page 29: ...se option Exige 195 50 R16 84W rear Elise std RE040 225 45 R17 90W AD07 225 45 R17 91W USA Elise AD07 225 45 R17 91W Elise opt Exige A048 225 45 R17 90W Pressure cold front 1 8 bar 26 lb in rear 2 0 bar 29 lb in Winter Tyres Type front Pirelli 210 Snowsport rear Pirelli 240 Snowsport Size front 195 50 R16 rear 215 45 R17 Pressure cold front 1 8 bar 26 lb in rear 1 9 bar 27 5 lb in Tyre studding No...

Page 30: ...4 1 max side side 0 35 Camber optimum 0 3 tolerance range 0 1 to 0 5 max side side 0 2 Alignment optimum Zero tolerance range 0 5 mm toe out to 0 5 mm toe in overall Geometry specification Elise option Exige Mid laden ride height reference height for geometry check front 120 mm below front end of chassis siderail rear 120 mm below rear end of chassis siderail Castor optimum 3 8 tolerance range 3 5...

Page 31: ...max side side 0 3 mm ELECTRICAL Light Bulbs Wattage Type Headlamps prior 07 main beam 55 H7 dip beam 55 H1 from 07 main beam 55 H7U dip beam 55 H7U 2011 Elise main beam 65 H9B dip beam 60 HB3A Driving lamps 55 H3 Front side parking lamps except 11 Elise 5 W5W 2011 Elise 5 x LED Side repeater lamps except 11 Elise 5 WY5W amber 2011 Elise LED Front turn indicators except 11 Elise 21 PY21w amber 2011...

Page 32: ...5 7 64 Second 2 05 1 90 1 91 7 7 12 4 8 73 14 1 8 79 14 1 Third 1 48 1 39 1 31 10 7 17 2 12 0 19 2 12 8 20 6 Fourth 1 17 1 03 0 97 13 6 21 8 16 2 26 0 17 3 27 9 Fifth 0 92 0 82 0 82 17 3 27 8 20 4 32 8 20 6 33 1 Sixth 0 81 0 70 19 4 31 3 24 0 38 6 Reverse 3 25 3 25 3 33 Final Drive 4 53 4 31 4 29 CLUTCH Type Single dry plate Diaphragm spring cover Hydraulic release Friction plate diameter 2ZZ 1ZZ ...

Page 33: ... height plate 6 notch Turning circle between walls excl mirrors 10 m between kerbs 10 8 m FUEL CONSUMPTION 1ZZ FE 2ZZ GE 1ZR FAE 1999 100 EC urban prior 2010 11 3 l 100km Elise R Exige 12 1 l 100km Elise SC 11 6 l 100km Exige S 12 3 l 100 km from 2010 10 6 l 100km Elise R 11 6 l 100km Elise SC 11 8 l 100km Exige S 11 9 l 100 km 8 3 l 100km extra urban prior 2010 6 5 l 100km Elise R Exige 6 8 l 100...

Page 34: ...Page 1 Lotus Service Notes Section AH CHASSIS SECTION AH Sub Section Page General Description AH 1 3 Chassis Straightness Check AH 2 4 Rear Subframe AH 3 5 ...

Page 35: ...SE CHASSIS UNIT Seat belt mounting frame steel roof hoop Composite Scuttle Seat mounting crash structure beam extrusion Seat belt mounting frame backstay Door hinge mounting Sill extrustion Main siderail Fuel tank bay Steel rear subframe a29b ...

Page 36: ...fixed closing panel with swaged lightening holes Note that this lower panel contributes to the structural integrity of the chassis such that the vehicle should not be operated without it fitted The rear ends of the siderails are joined behind the engine bay by a galvanised sheet steel fabricated subframe which provides mountings for the rear suspension pivots nad damper abutment engine rear stabil...

Page 37: ...face of each chassis main side rail At the front end between the suspension wishbone pivots and at the extreme rear end of each rail 2 Measure the height of each tooling hole above the reference plane and use jacks to adjust the height of the chassis in order to equalise any three of these dimensions 3 Measure the deviation of the fourth dimension from the other three Maximum service deviation 2 0...

Page 38: ...nd release from the subframe the oxygen sensor harness wheel speed sensor harnesses and brake pipes 5 Release the engine rear stabiliser mounting from either the subframe or transmission 6 Release the roof hoop backstays from the subframe Remove the two bolts each side securing the subframe to the chassis flange and withdraw the subframe from the car Fitting rear subframe When bolting the subframe...

Page 39: ...al Description BQ 1 3 Lotus Composite Body Features BQ 2 3 Bodycare BQ 3 4 Accident Damage Assessment BQ 4 5 Body Panel Bonding Materials BQ 5 6 Replacement of Bonded On Panels General BQ 6 9 Front Crash Structure BQ 7 10 Windscreen Frame BQ 8 12 Sill Panels BQ 9 16 Rear Bulkhead BQ 10 17 ...

Page 40: ...ction BQ Body Panels Door shell Windscreen Sill panel Front access frame panel Rear window shroud Engine cover lid Front clamshell Cabin rear Door hinge bulkhead cover panel Rear clamshell Front crash structure Chassis frame b277b ...

Page 41: ...the rear body aft of the doors These two clamshells are fixed using threaded fasteners to permit easy removal for access to chassis or powertrain components or to allow simple and economic accident repair Other composite mouldings include the door shells sills front compartment lid windscreen frame and rear bulkhead some panels being bonded to the aluminium alloy chassis with an elastomeric adhesi...

Page 42: ...pact and result in paint chips especially around the vulnerable frontal panels Do not follow other vehicles too closely in such circumstances Washing Lotus recommends that the car be hand washed using the following instructions Many contaminants are water soluble and can be removed before any harm occurs by thorough washing with plenty of lukewarm water together with a proprietary car wash additiv...

Page 43: ...nels are secured by threaded fasteners and are easily removed for access to the back of any damaged area for repair by conventional composite techniques Instructions for the removal and refitment of these panels are contained in section BR Bonded on Panels Windscreen Frame LH RH Sill Panels Front Crash Structure Rear Bulkhead These panels are bonded to the chassis or to other panels using a flexib...

Page 44: ...rt 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 dry wipe Primer Betapnme 5404 Lotus part no A...

Page 45: ...E cap Application The residual adhesive bead should be cut with a scalpal to leave an even thickness of ap proximately 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 Ad...

Page 46: ...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 componen...

Page 47: ... has to be touched or manipulated for any reason use only wetted fingers BQ 6 REPLACEMENT OF BONDED ON PANELS GENERAL Bonded body panels are secured using the Dow Chemical products Betaseal or Betamate which are flexible polyurethane adhesives which must be cut in order for a panel to be removed The recommended method of adhesive cutting is with the use of a pneumatic tool such as the Chicago Pneu...

Page 48: ...nt crash structure consists of an upper and lower moulding bonded together and supplied only as an assembly It is bonded to the front face of the chassis and is braced by an alloy undershield screwed to the bottom front edge of the chassis and to each lower side of the crash structure The unit also acts as a ducting for the engine cooling radiator and a c condenser if fitted which are mounted hori...

Page 49: ...ts of the structure rendering the unit unsuitable for refitment Take care not to damage the surface of the chassis when cutting the adhe sive 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 Pr...

Page 50: ...ndershield radiator see sub section KH 4 front clamshell see sub section BR 5 and remaining parts BQ 8 WINDSCREEN FRAME The windscreen frame is a single ICSRTM moulding with hollow foam filled sections and incorporates a forward extending buttress at each side to brace the frame against the front chassis A separate dash baffle panel is used to bridge the space between frame underside and chassis s...

Page 51: ...move the windscreen see sub section BR 14 3 Remove the instrument binnacle and fascia top panel see sub section BR 13 and release the fixings between dash upper extrusion and screen frame 4 Release the brake hose pipe connector at the front end of each buttress on the windscreen frame Release all harnesses and other components from the windscreen frame buttresses as necessary 5 Remove the wiper mo...

Page 52: ...lean 3900 see sub section BQ 5 Prime the header rail with Betaprime 5404 but do not prime the bracket Generously coat the bonding surface of the bracket with a 50 50 mix of Betamate 7064S A116B0159V and Betamate 7014 A116B0158V Fit the bracket to the header rail and wipe off extruded adhesive with Betaclean 3900 Position the bracket using tool T000T1422F RH or T000T1423F LH which sould be taped to...

Page 53: ...Page 15 Lotus Service Notes Section BQ Windscreen frame bonding sills not shown Windscreen frame Windsceen frame buttress Dash baffle panel Bonding path b281a ...

Page 54: ... bracket BR 8 2 Remove the door latch striker pin and washers noting the assembly sequence Remove the door sill trim panel from the chassis and the door ajar switch from the sill panel 3 Use a sealant cutting knife to cut the adhesive bead between sill and chassis body panels Note In the front wheelarch area a short section of the sill flange underlaps the windscreen frame buttress flange Unless t...

Page 55: ... Betaprime 5404 see sub section BQ 5 Prepare surface of the old adhesive bead on the chassis and body panels Using Betawipe 4000 see sub section BQ 5 8 Apply a bead of Betaseal mate adhesive see sub section BQ 5 to the bonding surface on the chassis and body and fit the sill panel into position first locating the sill bottom edge into its chassis slot and press all around the joint to ensure suffi...

Page 56: ...Fuel filter mounting bracket Rear window glass All the above components are bonded using elastomeric adhesive applied as follows Refer also to sub section BQ 5 Brackets Studplates Clean the bonding surfaces on the bracket and bulkhead with Betaclean 3900 black cap and prime both surfaces with Betaprime 5404 red cap Apply Betaseal 1701 adhesive to the bracket and clamp in position until the adhesiv...

Page 57: ... bonded to the bulkhead only at its centre section Clean and prime the centre section on the bulkhead with Betaclean 3900 and Betaprime 5404 and apply Betaseal 1701 Press the insulator panel into position and ensure sufficient compression of adhesive Tape in place until the adhesive has cured Refit remaining components in reverse order to removal ...

Page 58: ... Hinge Cover Panel BR 5 9 Front Clamshell BR 6 9 Rear Clamshell BR 7 11 Door Mirrors BR 8 12 Door Shell Brackets BR 8a 13 Door Beam Hinge BR 9 14 Door Shell Assembly BR 10 16 Door Glass Guide Rails Winder Mechanism BR 11 17 Electric Windows BR 12 21 Door Seals BR 13 23 Door Latch Mechanism without CDL BR 14 24 Central Door Locking BR 15 27 Instrument Binnacle Dash Panel BR 16 28 Windscreen BR 17 3...

Page 59: ...providing the cooling airflow for the chargecooler The roof panel may be removed for better access to the interior for servicing and the car may be driven without the roof fitted but wind buffeting and increased noise levels will be experienced together with a slight decrease in maximum power on supercharged cars Soft Top Roof A hollow composite roof siderail is used on each side of the car to bri...

Page 60: ... win dows 2 On the inside face of the right hand roof side rail locate the two latch release levers Pull the two lever handles towards each other to release the side rail latches press down on the side rail if necessary to relieve the load on the latch pins and rotate the rail upwards to release the canopy tension 3 Repeat step 2 for the left hand side rail Note Releasing the right hand roof side ...

Page 61: ...y parked 1 Open both doors and preferably with the aid of an assistant lower the roof onto the car holding aside the loose tethered fixings to avoid their entrapment or their causing paint damage Position the rear edge of the roof first before lo cating the front edge against the windscreen header rail 2 Locate a front spigot bracket into its latch plate lower slot lifting the roof slightly to all...

Page 62: ...e the panel 3 Using the special tool supplied slacken the Torx screw securing each front corner spigot bracket to the roof but do not yet remove the screws 4 Pull off the trim cover from each rear cor ner of the roof panel and remove the screw se curing the hook bracket to the latch plate at each rear corner 5 Remove the two front corner bracket fixing screws and lift the front edge of the roof sl...

Page 63: ...en the brackets and the bulhead Each rear leg of the shroud is fitted with a captive M6 stud which locates through a hole in the clamshell buttress with the retaining nut accessible either from the engine bay or wheelarch area A foam gasket is used to prevent chafing damage between the shroud and clamshell When removing the shroud it is also necessary to peel off the rear weatherstrip from the fro...

Page 64: ...sed to attach the lid to the rear bulkhead with stud plates fixing the hinges to the bulkhead from the engine bay side and the nuts accessible from the cabin after removal of the rear bulkhead trim panel A single key operated latch mechanism secures the lid to a striker pin mounted on the clamshell engine boot bulkhead The latch is released by inserting the ignition key into the lock and turning c...

Page 65: ... spring strut to support the lid in the fully open position The latch mechanism is mounted on the boot bulkhead where it and an adjacent alarm plunger switch are protected by a steel heat shield The latch is operated by a cable release from a lever handle mounted outboard of the driver s seat back A rear aerofoil with integrally moulded support struts is secured to the rear end of the tailgate and...

Page 66: ...he single screw securing the door hinge cover panel to the clamshell Release the repeater lamp harness and withdraw the panel BR 6 FRONT CLAMSHELL The front clamshell is a bonded assembly of several glass fibre composite mouldings incorporating both front wings the front access aperture radiator air intake and headlamp housings The clamshell is secured to the windscreen frame radiator mounting pan...

Page 67: ...hell channel to the radiator air deflector panel 7 If fitted remove the single fixing at the bottom front of each wheelarch securing the clamshell to the radiator panel extension not used on oil cooler cars 8 Remove the headlamp cover mask assembly from each side by releasing the three socket head screws inside the wheelarch Remove the clamshell fixing at the front of each headlamp housing Release...

Page 68: ...he cabin remove the two screws above the rear window securing the top edge of the clamshell to the rear bulkhead Remove the two cant rail latch plates from their brackets on the roof hoop Peel off the weatherstrip seal from the clamshell flange 4 From inside the cabin remove both seats and the full width trim panel from the rear bulkhead From the access thus provided remove the fixing securing the...

Page 69: ...shell boot floor and the exhaust muffler corrugated heat shield bolted to the sub frame The corrugated shield must touch neither the muffler nor the clamshell mounted shield or heat dam age may be caused to the clamshell On factory build the subframe is marked adjacent to each of the four clamshell mounting points with the shim thickness required Shim plates are available in 1mm and 2mm thicknesse...

Page 70: ...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 The plinth is secured to the door outer panel with access holes for the three screws provided in the inner panel cosmetically con cealed by adhesive patches Note ...

Page 71: ... The hinge stator or hinge bracket is bolted to an outrigger on the chassis and incorporates two cylindrical bearing housings fitted with maintenance free pivot bushes Door hinge adjustments In order to provide for adjustment of door shutlines the door hinge may be adjusted in two ways i Height of the hinge its fore aft position and the pivot axis angle to control the front rear height align ment ...

Page 72: ...f the spring plate to provide for maintenance free operation with the shoe moulding clamped between the spring plate and chassis To help protect the hinge mechanism from water and dirt ingress a plastic shield is push fitted over the retaining nuts for the spring plate To remove the door assembly or for access to the door pivot components the two M10 cap head rotor bush retaining screws should be ...

Page 73: ...l is secured to the beam via three screws through a flange at the front end of the beam tapping into nut plates bonded into the door shell and via two bolts at the rear end of the door to the door beam extension bracket Access to the two bolts securing the extension bracket to the door beam requires that the door glass first be released 1 Remove the window winder handle and door trim panel manual ...

Page 74: ...he primary scissor leg carries a toothed sector which is engaged by a pinion on the window winder The front and rear edges of the glass are guided by steel rails which engage with point contact Nylon guide blocks bonded to the glass The bottom ends of the rails are adjustable in out to set the inward tilt of the glass with the up glass position controlled by an eccentric stop on the winder mechani...

Page 75: ...hannel Nylon guide block Door glass Guide rail Scissor Door Steel guide tilt top fixing linkage glass rail Adjuster Handle pinion screw Reaction Toothed sector channel Threaded block fixed Door to rail anchorage point b285a Threaded block fixed to door shell ...

Page 76: ...with jig bonded Nylon sliders and stud plate 5 Fit the new glass into the door and re assemble in reverse order to the above 6 Adjust the glass position as detailed above To replace door winder mechanism 1 Remove the window winder handle and the door trim panel 2 Release the interior release control rod from the door handle and unclip from the latch mechanism 3 Secure the door glass in the fully r...

Page 77: ...he front and one for the rear edge Each of the steel black zinc plated guide rails is secured by a single screw at the top end to a jig bonded bracket in the door shell and by a threaded adjuster at the lower end engaging in a threaded block fixed to the door shell Screwing the adjusters in or out will set the inward tilt of the glass and the contact between glass and door weatherseal To remove a ...

Page 78: ...oor shell A single drive cable running from the window lift block around a guide channel pulley through a flexible conduit around the motor driven winder drum through another conduit around the second guide channel pulley and back to the window lift block An adaptor plate bolted to the stud plate on the lower edge of the door glass Door Glass Adjustment The door glass guide channels and adjustment...

Page 79: ...in the top of the door shell 4 Unplug the motor electrical connector Release the three fixings securing the motor mounting bracket and the two remaining fixings securing the guide channel to the door shell 5 Carefully manoeuvre the lift mechanism from the door 6 Refit in reverse order to removal noting that the motor mounting bracket is fixed directly against the door shell but that 4mm plastic sp...

Page 80: ...e cheater seal and fit onto the door Door Weatherstrip A hollow section rubber weatherstrip is bonded around the door aperture and roof landings to seal against the door shell and roof Different seal configurations are used for the door and roof areas with specially moulded sections to interface with the roof cantrails The seal is divided into front and rear sections with a joint at the bottom fro...

Page 81: ...n backing strip and secure the seal along the roof shroud flange Use a roller wheel along the whole length of the seal to ensure full adhesion A secondary J section seal is applied to the front vertical face of the door shell linking to the cheater seal BR 14 DOOR LATCH MECHANISM Without CDL Parts List 10 17 Interior release handle Exterior release Relay lever button Interior release assembly cont...

Page 82: ...s connected to the latch mechanism by a control rod No interior control of door locking is provided Interior Release Handle Remove the window winder handle and door trim panel Remove the four screws securing the interior handle assembly and unclip the control rod end clip to allow the rod to be unhooked from the handle On refitting ensure that the control rod is located in the guide clips Exterior...

Page 83: ...r mechanism Remove the window winder handle and door trim panel 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 waist seals Remove the access grommet from the rear face of the door and unclip the exterior lock link rod from the relay lever Similarly...

Page 84: ...t of a vehicle collision which causes the safety inertia switch to be tripped the doors will automatically be unlocked Notes In the event of a flat vehicle battery the central door locking will not operate The doors can be unlocked only after opening the boot lid and restoring power to the battery by substitution re charging or jumping to a second battery To lock the car with a flat or disconnecte...

Page 85: ...aker or door sill trim panel mounting brackets On non airbag cars a skinned foam fascia top panel trimmed with suede material joins the top of the dash to the base of the windscreen and incorporates the demist ducting and four windscreen outlet vents with a moulded plastic capping panel around the front of the fascia top and surrounding the vents At each end of the fascia a moulded plastic panel j...

Page 86: ... the fascia top 7 Lift the rear of the fascia top to release the two locating bosses from the keyhole slots in the dash and pull the fascia rearwards to withdraw the two front edge spigot pins 8 If the demist ducting is found to have become detached or loose from the facia top foam moulding the duct should be refixed as follows Remove any fixing screws separate the duct from the fascia and remove ...

Page 87: ...el fixing Fascia top panel Dash fixing to screen frame Column shroud Fascia to dash fixing Fascia top FLV climate recess finisher control housing Dash lower extrusion Keyhole slot for fascia Audio set support Dash upper extrusion Fascia top Upper centre extrusions Chassis scuttle beam Lower extrusion b202a ...

Page 88: ...ack mounting bracket Column shroud support leg Fascia top panel Column shroud Dash fixings to screen frame FLV audio housing Climate control Airbag housing door Airbag shute Dash upper extrusion Dash lower extrusion Audio set support Rivet to scuttle beam pl1405mtb ...

Page 89: ...es out 1 Column shrouds Remove the two screws retaining the top part of the shroud and the four screws retaining the lower part and withdraw both parts from the column 2 Instrument shroud Pull the instrument shroud backwards to release the four spring clips from their apertures in the dash panel 3 Sill top trims Release the two screws at the bottom of the coin pockets at the front of each sill and...

Page 90: ...h Adhesive Kit A116U0194S 1 On non airbag cars to minimise the possibility of trim damage remove the fascia end speaker panels and the fascia top capping panel around inside base of windscreen 2 Remove the front clamshell see sub section BR 6 3 Remove the wiper arm from its spindle and the interior mirror from its plinth 4 Cut around the whole length of the windscreen surround finisher to allow ac...

Page 91: ...taprime around the inside periphery of the glass Similarly apply to the whole of the bonding surface on the windscreen frame and to the windscreen bottom laminated edge Allow to dry for a minimum of 5 minutes If the screen is not fitted within 48 hours the primer should be re applied 11 Cut the nozzle of the Betaseal cartridge to the dimensions shown to produce a triangular section bead Holding th...

Page 92: ...sher spacers and bottom edge spacer blocks is felt Carefully examine the integrity of the whole length of the joint if necessary using a spatula to force extra adhesive into any suspect areas Wipe off any excess adhesive extruded from the joint or alternatively allow the adhesive fully to cure and cut away any excess using a scalpel blade 14 Use duct tape and or support blocks to hold the screen i...

Page 93: ...oved with either Wipe Cleaner No 4 or white spirit Shelf life a Betaseal primer has a useful life of about 24 hrs after exposure to the air after which it starts to become spongy If the material is spongy DO NOT USE Always use glass primer immediately on opening and replace the lid after use b Betaseal has a shelf life of over 6 months at ambient temperature in the original unopened package ...

Page 94: ...tion CI FRONT SUSPENSION SECTION CI Sub Section Page General Description CI 1 3 Geometry Adjustments CI 2 3 Anti Roll Bar CI 3 7 Suspension Disassembly Assembly CI 4 9 Front Wheel Bearings CI 5 11 For Super Sport Suspension see DH 6 ...

Page 95: ...Section CI GENERAL LAYOUT Spring damper unit Top wishbone Steering tie rod Upper swivel joint Track rod end Steering arm Anti roll bar mounting Anti roll bar Bottom wishbone Hub carrier Wheel hub Lower steering swivel joint c34b ...

Page 96: ... lower wishbones CI 2 GEOMETRY ADJUSTMENTS Provision is made for the adjustment of wheel alignment camber and castor Under normal service con ditions no periodic scheduled check of the geometry is necessary although a front wheel alignment check is recommended when the front tyres are replaced A full geometry check is required only after front suspension repair or if excessive tyre wear is evident...

Page 97: ... 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 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 qu...

Page 98: ...ive tyre wear Camber adjustment is effected by adding or deleting shim plates between the steering arm to which the upper steering swivel joint is fixed and the hub carrier Shimplates are available in 1mm and 3mm thicknesses Reducing the shim pack thickness will increase negative camber Adding shims will reduce negative camber A 1mm shim plate will alter camber by approximately 0 25 In March 04 th...

Page 99: ...the pick up points in which are reinforced either with machined inserts or in the case of the foremost position a thick alloy plate each being bonded to the chassis with epoxy adhesive Spacer washers are fitted ahead of and behind each of the top wishbone pivot bushes to allow the wishbone to be displaced forwards or backwards with an associated change of castor angle A rubber faced snubber washer...

Page 100: ...ball jointed links The bar is mounted to the chassis using rubber pivot bushes for noise isolation retained by alloy clamp brackets Washers welded to the bar bear against the inner sides of the bushes to provide lateral location of the bar Castrol LMX rubber grease or equivalent should be used when fitting the rubber bushes onto the anti roll bar 2 On Elise and Exige models built with Super Sport ...

Page 101: ...ard bar but using hard plastic bushes housed in alloy clamps Each split pivot bush incorporates a raised shoulder around its centre in order to engage with a groove in the two part clamp and provide lateral location of the bush A pip on this shoulder locates in a hole in the clamp cap to prevent rotation of the bush No lubrication is required These hard bushes benefit dynamic response at some pena...

Page 102: ...teering rack to full lock to provide clearance for the withdrawal of the wishbone rear pivot bolt Withdraw the wishbone 10 The wishbone pivot bushes comprise a rubber bush bonded to a steel inner sleeve and a flanged plastic outer sleeve The bushes may be pressed out of the wishbone eyes and new bushes fitted using suit able press tool dollies Smear the outer surface of the new bush with IPC P 80 ...

Page 103: ...ses the lower ball joint and the two bolts securing the upper ball joint plinth to the hub carrier are renewed The Service Schedule specifies that the security of the front and rear suspension is checked at each service For cars used on race tracks or in similar conditions suspension components and torque checks should be carried out between sessions This operation requires that all the principal ...

Page 104: ...mber shim plate bracket If there is found to be any discernible free play in the hub bearing or any roughness or tight spots can be felt or any signs of lubricant expulsion are evident the hub assembly should be replaced there is no provi sion for adjustment To Replace Hub Bearing Assembly 1 With the wheel removed release the two fixing bolts and remove the brake calliper from the hub carrier Supp...

Page 105: ...R SUSPENSION SECTION DH Sub Section Page General Description DH 1 3 Geometry Adjustments DH 2 3 Suspension Disassembly Assembly DH 3 6 Rear Wheel Bearings DH 4 9 Track Use Chassis Rear Brace Kit DH 5 11 Super Sports Suspension Package DH 6 14 ...

Page 106: ... Notes Section DH Rear Suspension Layout Damper top mount Upper ball joint Damper Hub carrier Top wishbone Rear subframe Rear subframe Lower wishbone Driveshaft Toe control link Wheel hub Road spring Lower ball joint d20b ...

Page 107: ...ntrol link shares a subframe anchorage with the rear pivot of the lower wishbone and at its outboard end is secured directly into a tapered hole in a rearward integral extension of the hub carrier The forged steel hub carrier provides a mounting for a hub bearing unit which is secured by three Torx head bolts and incorporates a wheel speed sensor for the anti lock brake system engine management an...

Page 108: ...line of the wheel D1 D2 If the front dimension D1 is greater than the rear dimension D2 the wheel has TOE IN If the rear dimension is greater than the front dimension the wheel has TOE OUT The difference between the two measurements is the amount the wheel has toe in or toe out Wheel alignment is adjusted via the toe control link which is equipped with a left hand threaded ball joint at the inboar...

Page 109: ...ive camber A 1mm shim plate will alter camber by approximately 0 3 In March 04 the caphead bolts securing the ball joint plinth to the hub carrier were upgraded from 8 8 to 10 9 grade with a corresponding increase in torque from 45 to 68 Nm Before fitting these bolts inspect the cap head for the grade marking apply Permabond A130 A912E7033 to the threads and torque tighten to the appropriate figur...

Page 110: ...ose Release the single retaining screw and remove the brake disc from the hub 4 Disconnect the wheel speed sensor cable from each hub unit and release from routing clips 5 Release the nut securing the outer end of the toe link to the hub carrier and use a ball joint separator to release the joint from the carrier 6 Remove the nut securing the ball pin of the lower ball joint to the hub carrier and...

Page 111: ...sh from the front end of the eye Note Prior to January 06 this bush was inserted from the rear end Inserting from the front provides greater restistance to bush displacement from braking forces Lower wishbone rear pivot insert a single 30mm long bush from the front end of the eye Lower wishbone front pivot insert a 16mm long bush into each end of the front eye 14 The road spring may be removed fro...

Page 112: ...the bolt head or nut In July 05 the thickness of the tab washer was increased from 1 2mm to 1 5mm If the lower wishbone front pivot brackets have been removed from the chassis ensure that a spacer is fitted on each of the four bolts securing each bracket in order to allow the required bolt stretch to be achieved Note that on previous Elise models there have been several variants of the toe link in...

Page 113: ... to have become loose and the car has been operated for any period in this condition the bolt should be renewed as a standard precaution and related components carefully inspected for hole ovality or wear At every service interval the toe link should be checked for free articulation by using a spanner on the flats of the link and twisting in both directions The torque required to articulate the jo...

Page 114: ...d withdraw the brake disc from the hub 3 Disconnect the wheel speed sensor harness from the hub unit 4 Using a Torx socket release the three bolts securing the hub bearing unit to the hub carrier and withdraw the unit from the hub carrier and driveshaft If necessary use a suitable puller tool to press the shaft from the hub but on no account allow an extension force to be applied to the driveshaft...

Page 115: ...0D0040H 1 Turnbuckle crossbrace adjustment A120D0039F 2 Locknut turnbuckle M12 RH thread A111W3150F 2 Locknut turnbuckle M12 LH thread A111W3149F 2 Flange Nut brace to subframe M10 A111W3151F 2 Adaptor Lug A120D0037F 2 Spherical Joint toe link inboard A120D0036F 2 Spacer spherical joint to subframe A120D0035F 2 Pivot Bolt toe link inboad M10x120x1 25p A120W2212F 2 Locknut pivot bolt M10x1 25p A117...

Page 116: ... tighten the toe link ball joint locknuts to 45 Nm Ensure ball joints are phased at 90 to each other to allow maximum joint articulation 10 Refit undertray and diffuser Section A thro lower link inboard fixing Heatshield Lower wishbone rear bush Adaptor lug Pivot bolt New spherical joint Self locking nut Special spacer washer d46a Welded insert Toe link Adaptor lug Turnbuckle Adjustable type cross...

Page 117: ...H Section B thro steady mounting attachment adjustable type crossbrace Engine steady mounting Cross brace welded bracket Chassis Cross brace tube d47 FRONT General view Cross brace fixing Adaptor lug to subframe Turnbuckle Cross brace d45 ...

Page 118: ...ght to 120 120mm To adjust the height first load the car to the mid laden condition with a full fuel tank and two 75 kg 12 stone passengers Then use the C spanners supplied with the car to screw the spring collars upwards on the damper body and drop the ride height as measured beneath the front and rear ends of each chassis main siderail To speed the attainment of this setting the spring collars s...

Page 119: ...crossbrace tube Forged Wheels The lightweight forged wheels offer a saving of 14 4 kg car on Elise and 20 4 kg car for Exige and feature a wider front rim width of 6 5J Insets are unchanged Yokohama A048 Tyres The Yokohama A048 tyres have been developed jointly by Lotus and Yokohama to suit the requirements of the performance driver with special emphasis on track use Compared with the standard tyr...

Page 120: ...g seat adjust A120C6001F 1 Cradle tie wrap reservoir mounting A082W6293F 2 Tie Wrap reservoir mounting A075W6038Z 4 Screw M5 x 20 cradle fixing A075W5084F 2 Rawlnut M5 cradle fixing A075W6074F 2 Anti Roll Bar stiffened adjustable A111C0134S 1 Black Mounting Clamp Nylon A111C0052F 2 Spacer Sleeve mounting clamp A111C0060F 2 Bolt M5 x 45 cap head clamp fixing A082W2106F 2 Washer flat M5 clamp fixing...

Page 121: ...he reinforcing brackets between the bot tom of the crash structure and the chassis Each split pivot bush incorporates a raised shoulder around its centre in order to engage with a groove in the two part clamp and provide lateral location A pip on this shoulder locates in a hole in the clamp cap to prevent rotation of the bush No lubrication is required Each bush housing is clamped to the front fac...

Page 122: ...ess fitting pre assembled spring damper units use spring compressor clamps to assemble the new springs and dampers taking all appropriate safety precautions Mount the rear units with the red dot on the damper lower body facing outboard Mount the front units in similar manner and secure each front remote reservoir to the front face of the body side using a saddle clip and two tie wraps as shown bel...

Page 123: ... track use Compared with the standard tyre the front tyre width is increased and the profile reduced from 175 55 to 195 50 The tyre tread design is di rectional such that each wheel tyre assembly is dedicated to a single vehicle corner Tyre pressures are unchanged The Lotus specific construction is identified by the letters LTS moulded on the tyre sidewall Ensure that any replacement tyre is so ma...

Page 124: ...on 1ZZ FE EH 2 9 Maintenance Operations 2ZZ 1ZZ EH 3 10 Engine Removal Replacement EH 4 13 Special Tools EH 5 15 Engine Management Component Location EH 6 16 2010 Elise 1ZR FAE Supplement EH 7 17 See also 2ZZ 1ZZ engine repair manual E120T0327J Toyota publication See also 1ZR FAE engine repair CD T000T1523F Toyota production ...

Page 125: ... Lotus Service Notes Section EH Page 2 Engine Sections 2ZZ GE From LH side From front Cylinder Head Section Exhaust side Inlet side e226 e227 ...

Page 126: ...ump via a by pass gallery in the cylinder head and block When the thermostat opens the by pass route is closed off and a greater volume of coolant flows via the heater matrix and throttle body as well as through the engine cooling radiator The die cast aluminium intake manifold draws air from a single throttle body with cable controlled but terfly valve into a plenum chamber from which the four in...

Page 127: ... Lotus Service Notes Section EH Page 4 e223 e224 e222 ...

Page 128: ...sponding high lift cam actuates a spring loaded tappet housed within the rocker arm and under low speed conditions has no effect on valve operation due to the clearance between the bottom of the tappet and the rocker arm When engine speed reaches 6 000 rpm at normal running temperature the ECU operates a spool valve on the back of the cylinder head to close an oil return line and raise oil pressur...

Page 129: ... Lotus Service Notes Section EH Page 6 e225 ...

Page 130: ...upplied from the inlet manifold The vacuum supply uses an in line non return valve and a reservoir incorporated into the front face of the airbox body to maintain flap closure during periods of low inlet depression A solenoid valve mounted on top of the airbox and connected into the vacuum capsule line is energised by the ECU when ap propriate to ventilate the capsule and open the valve Airbox fla...

Page 131: ...A pivotted hook on the tensioner body is provided to aid assembly by enaging with a pin on the spring plunger to hold the assembly retracted whilst fitting After fitment to the timing cover the engine is then turned backwards so that the chain forces the plunger into the tensioner body which action pushes the hook into a disengaged position and allowing tension to be applied on resumption of norma...

Page 132: ...ast iron cylinder liners 2ZZ uses integrated MMC cylinder walls Manifolds The inlet manifold is moulded in plastic to reduce weight and heat transference and incorporates a resona tor feature to optimise gas pulsations for mid range performance A unique adaptor is used to link the manifold to the electronic throttle body which differs from the 2ZZ and other 1ZZ types The simplified exhaust manifol...

Page 133: ...cessary The difference between high and low dipstick marks is equivalent to 1 5 litre Allow several minutes for the oil to drain through to the sump before re checking the oil level Do NOT overfill or lubrication will be degraded and consumption increased as the oil becomes aerated Refit the filler cap turning clockwise until secure Engine Oil Change The use of high quality oil renewed at the spec...

Page 134: ...e maintenance operations In instances of major engine failure where the oil system may be contaminated with metallic debris all oil cooler lines should be thoroughly flushed out and the oil cooler radiators replaced If the oil cooler circuit is drained or re placed the following procedure should be adopted to fill the cooler system before starting the engine 1 Attach a tube to the bleed nipple on ...

Page 135: ... Refit the wheelarch liner and rear wheel Auxiliary Drive Belt A single multi rib serpentine type belt is used to transmit drive from the crankshaft to the water pump alternator and a c compressor with a slave pulley fitted in place of the power steering pump used in other applications A hydraulically damped spring loaded tensioner arm applies tension to the back of the belt and is maintenance fre...

Page 136: ...idual fuel pressure Disconnect the battery It is recommended first to release the quick fit connector located to the rear of the coolant header tank Release the retaining clip securing the pipe joint to the header tank bracket Slide the orange coloured safety lock to allow access to the connector release buttons Surround the pipe joint with a shop towel to absorb fuel contained in the pipework bef...

Page 137: ...e the bracket complete with tank and recirc pump Release the purge pipe from the throttle body 11 Remove the LH driveshaft from the transmission Release the top ball joint plinth from the LH hub carrier noting and retaining the camber adjustment shims and separate the toe link ball joint separated from the carrier The driveshaft inboard joint is retained in the transmission by a round section circ...

Page 138: ...y insert the driveshaft into the transmission with on the left hand shaft the two ends of the circlip positioned lowermost and rotate the shaft if necessary to engage the splines Press the inboard joint outer until a click indicates the engagement of the retaining circlip if necessary using a brass drift and hammer Pull on the body to ensure its security On the right hand shaft fit the bolts secur...

Page 139: ...ensor 7 Oil control valve for variable valve timing 8 Crankshaft position sensor 9 Plug top coil 10 Coolant temperature sensor 11 Pre catalyst oxygen sensor 12 Post catalyst oxygen sensor 13 Oil pressure switch 14 Throttle position sensor 15 Vacuum solenoid for intake flap valve 16 Mass airflow sensor 17 Idle Air Control IAC valve prior 06 M Y For component replacement procedures refer to manual B...

Page 140: ...ylinder head and a crankshaft cylinder axis offset désaxé of 8mm to reduce piston side thrust on the power stroke Engine Sections From LH side From front 1ZR The Acoustic Control Induction System ACIS uses a bulkhead within the intake plenum to divide each of the four intake tracts into two sections For each tract an intake air control valve under common control provides either a long or short tra...

Page 141: ...nd intake plenum throttling at high speeds Max engine speed 6800 rpm continuous 7000 rpm transient Spark plugs Denso SC20HR11 Spark plug gap 1 0 to 1 1mm Compression std 1373 kPa 14 0 kgf cm2 199 psi or higher min 1079 kPa 11 0 kgf cm2 156 psi max diff 98 kPa 1 0 kgf cm2 14 2 psi Notes Valve lift actuator driven off tail of inlet camshaft Vacuum pump driven off tail of exhaust camshaft to supply b...

Page 142: ...the rotary cam profile at all times The position of the oscillating cams at the start of a valve opening event however is dependent on their phasing with the roller arm In the low lift mode where the cams are phased counterclockwise in relation to the roller arm as viewed from the rear the finger follower roller is in contact with the base circle of the oscillating cam which must turn through a la...

Page 143: ...ncept to the Evora and is mounted at the right hand rear of the engine accessible from beneath after removal of the engine bay undertray Make provision for collecting the small amount of spilled oil before fitting adaptor tool T000T1441F over the cap to release the security catch and allow it to be unscrewed using a 17mm wrench or 3 8 inch square drive Release about 4 turns before positioning the ...

Page 144: ...e List EMP 1 3 Diagnostic Scanner Tools EMP 2 43 Engine Management Component Location EMP 3 47 Mechanical Throttle Setting Procedure EMP 4 48 2006 Model Year Electronic Throttle Control EMP 5 49 Diagnostic Trouble Code Supplement 06 M Y EMP 6 50 Diagnostic Trouble Code Supplement 2011 M Y Elise Euro 5 EMP 7 58 ...

Page 145: ...age Pre Catalyst 15 P0132 O2 Sensor Circuit High Voltage Pre Catalyst 15 P0133 O2 Sensor Circuit Slow Response Pre Catalyst 15 P0134 O2 Sensor Circuit No Activity Detected Pre Catalyst 15 P0135 O2 Sensor Heater Circuit Pre Catalyst 15 P0137 O2 Sensor Circuit Low Voltage Post Catalyst 18 P0138 O2 Sensor Circuit High Voltage Post Catalyst 18 P0139 O2 Sensor Circuit Slow Response Post Catalyst 18 P01...

Page 146: ...Than Expected 35 P0507 Idle Air Control System RPM Higher Than Expected 35 P0508 Idle Air Control System Circuit Low 35 P0509 Idle Air Control System Circuit High 35 P0562 System Voltage Low 36 P0563 System Voltage High 36 P0601 Watchdog 37 P0606 Checksum 37 P0627 Fuel Pump Control Circuit Open 38 P0646 A C Clutch Relay Control Circuit Low 39 P0647 A C Clutch Relay Control Circuit High 39 P1301 Mi...

Page 147: ... valve will hold the valve current timing by preventing oil flow from the VVT controller housing a duty cycle less than 50 will retard the valve timing a duty cycle greater then 50 will advance the valve timing Component connections Sensor Connector Description ECU Pin ECU Connector 1 Battery Voltage 2 VVT Oil Control Valve 49 J3 52 Way Right 06 M Y in brackets P0011 P0012 Monitor Continuous Enabl...

Page 148: ... Battery Voltage 2 MAF Ground 31 D2 52 Way Right 3 MAF Signal 45 B4 52 Way Right 06 M Y in brackets 4 IAT Signal 44 B3 52 Way Right 5 IAT Ground 18 D2 52 Way Right Sensor characteristics 0 655 g sec Typical values 1 5 5 0 g sec idle 5 0 15 0 g sec 2500rpm elevated idle no load Monitor Continuous P0101 Enable Criteria Engine running Engine speed 2490rpm TPS 80 P0101 MAPS too low TPS 5 P0101 MAPS to...

Page 149: ...en circuit MAF value g sec 0 0 MAF sensor signal open circuit or short to ground MAF value g sec 0 0 MAF sensor ground open circuit MAF value g sec 229 0 Notes The MIL will be illuminated if the faults are present for 2 consecutive trips Further information on the sensor may be found in Toyota 1ZZ FE 2ZZ GE manual RM733E B120T0327J Page DI 26 to DI 32 ...

Page 150: ...d measures atmospheric pressure This parameter is required to compensate the mass air flow when the vehicle is operated at higher altitudes Monitor Continuous P0106 Enable Criteria Engine running Engine speed 2190 3510rpm TPS 80 Disable Criteria P0101 P0102 P0103 MAF Sensor fault codes P0121 P0122 P0123 P0222 P0223 P2135 Throttle Pedal position fault codes Potential failure modes Sensor failure P0...

Page 151: ...so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Battery Voltage 2 MAF Ground 31 D2 52 Way Right 3 MAF Signal 45 B4 52 Way Right 06 M Y in brackets 4 IAT Signal 44 B3 52 Way Right 5 IAT Ground 18 D2 52 Way Right Sensor characteristics IAT 20 C 4 F 12 5 16 9 kΩ IAT 20 C 68 F 2 19 2 67 kΩ IAT 60 C 140 F 0 50 0 68 kΩ Monitor Continuo...

Page 152: ...eria None Potential failure modes Signal open circuit IAT 140 C 284 F 4 932 V Sensor failure Notes The MIL will be illuminated if the fault is present for 2 consecutive trips Further information on the sensor may be found inToyota 1ZZ FE 2ZZ GE manual RM733E B120T0327J pages DI 33 to DI 38 ...

Page 153: ...nsor connections Sensor Connector Description ECU Pin ECU Connector 1 Ground 7 H1 52 Way Right 06 M Y in brackets 2 Signal 33 C3 52 Way Right Sensor characteristics 0 C 32 F 3 279 V 19 4 C 67 F 2 186 V 42 5 C 108 5 F 1 249 V 80 C 176 F 0 469 V P0116 Enable Criteria Engine running 800 seconds Disable Criteria None Potential failure modes P0117 signal short circuit P0118 signal open circuit Sensor f...

Page 154: ...es Section EMP Page 11 Notes The MIL will be illuminated if the fault is present for 2 consecutive trips Further information on the sensor may be found inToyota 1ZZ FE 2ZZ GE manual RM733E B120T0327J page DI 39 to DI 45 ...

Page 155: ...2 5V Ref 8 M4 52 Way Right 06 M Y in brackets 3 TPS1 Signal 20 D3 52 Way Right 4 TPS2 Signal E3 Right Sensor characteristics 0 0 595 V 5 100 4 148 V 5 Monitor Continuous P0121 Enable Criteria Rationality check throttle not too high at low engine load Engine running TPS 80 Engine speed 1500rpm MAPS 40 Vehicle Speed 30 km h 18 6mph OR Rationality check throttle not too low at high engine load Engine...

Page 156: ...o ground Sensor failure P0123 Enable Criteria None Disable Criteria P0016 Crankshaft Camshaft position correlation error Potential failure modes Signal open circuit 4 487 V Reference voltage open circuit Reference voltage short to ground Sensor failure Notes The MIL will be illuminated if the fault is present for 2 consecutive trips Further information on the sensor may be found inToyota 1ZZ FE 2Z...

Page 157: ...ngine start and monitors the rate of temperature rise during warm up relative to the measured engine air flow Monitor Continuous Enable Criteria Engine running Coolant Temperature 10 C 14 F Coolant Temperature 70 C 158 F Disable Criteria P116 P117 P118 Engine Coolant Temperature sensor faults Potential failure modes Thermostat failure Notes The MIL will be illuminated if the fault is present for 2...

Page 158: ...ce in electrical potential to develop between the two plates Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaust gases Thus when the air fuel mixture is rich the oxygen sensor output will be high If the air fuel mixture is lean the oxygen sensor output will be low Sensor connections Sensor Connector D...

Page 159: ...P0101 P0102 P0103 MAF sensor faults Monitor Monitored until the required amount of switches in both directions has been achieved Approx 150 sec Potential failure modes Sensor connector and wiring should be checked for corrosion and loose connections Sensor contaminated possibly from fuel improper use of RTV engine oil or coolant P0134 Set when the sensor fails to switch above 557mV 06 M Y 675mV an...

Page 160: ... connector and wiring should be checked for corrosion and loose connections Notes The MIL will be illuminated if the fault is present for 2 consecutive trips Further information on the sensor may be found inToyota 1ZZ FE 2ZZ GE manual RM733E B120T0327J pages DI 53 to DI 62 ...

Page 161: ...s the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaust gases Thus when the air fuel mixture is rich the oxygen sensor output will be high If the air fuel mixture is lean the oxygen sensor output will be low The post catalyst oxygen sensor performance is a good indicator of catalyst efficiency Sensor connect...

Page 162: ... either passed or failed Potential failure modes Check and rectify any pre catalyst sensor fault code as they may be causing the fault code to be set Catalyst P0140 Set when the sensor fails to switch above 557mV and below 400mV within 60 seconds Enable Criteria Engine run time 30 seconds Engine is not at idle Engine is in closed loop fuel control Monitor Continuous Potential failure modes Check a...

Page 163: ...lts P0131 P0132 P0133 P0134 P0135 Oxygen sensor faults P0300 P0301 P0302 P0303 P0304 Misfire faults P0441 P0442 P0443 P0447 P0448 P0450 P0451 P0455 P0456 EVAP faults Monitor Continuous Malfunction Criteria P0171 This code is set when the calculated fuel demand has been increased to its maximum limit of 17 and the system still cannot maintain an air fuel ratio of 14 7 1 under normal driving conditi...

Page 164: ... connections Injector ECU Pin ECU Connector 1 25 J1 52 Way Right 2 51 K4 52 Way Right 06 M Y in brackets 3 14 K3 52 Way Right 4 40 K2 52 Way Right Malfunction Criteria The operation of all the injector codes is the same the last digit relates to the injector involved i e a code P0203 indicates there is a problem with injector number 3 Enable Criteria Engine running Monitor Continuous Limp home Lim...

Page 165: ...F3 22 F3 22 F3 22 F3 52 Way Right 3 Coil Output Logic 52 G1 26 G4 47 G3 48 G2 52 Way Right 4 Ground Malfunction Criteria The operation of all the misfire codes is the same the last digit relates to the misfire involved i e a code P0303 indicates there is a problem with coil number 3 P0300 indicates the misfire is random and not linked to one particular cylinder Enable Criteria Battery voltage betw...

Page 166: ...es Section EMP Page 23 Notes The MIL will be illuminated if the fault is present for 2 consecutive trips Further information on the sensor may be found inToyota 1ZZ FE 2ZZ GE manual RM733E B120T0327J pages DI 73 to DI 78 ...

Page 167: ...en spark knock and other similar sounding noises Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor input 43 C4 52 Way Right 06 M Y in brackets 2 Ground 13 A4 52 Way Right Malfunction Criteria P0327 This code is set when the knock sensor signal is 0 586 V P0328 This code is set when the knock sensor signal is 2 928 V Potential failure modes Abnormal engine noise i e dam...

Page 168: ... is also used to determine misfires events Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor input 4 E1 52 Way Right 06 M Y in brackets 2 Ground 30 E4 52 Way Right Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes Sensor signal open circuit or short to ground Sensor ground open circuit Sensor failure Notes If a sensor or se...

Page 169: ...variable position camshaft tooth As the engine speed and the position is known from the crankshaft sensor signal the camshaft position can be calculated Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Signal VR Input 16 C1 52 Way Right 06 M Y in brackets 2 Ground 42 E2 52 Way Right Monitor Continuous Enable Criteria Engine running Engine speed 600rpm Disable Criteria None P...

Page 170: ...ransistors in the igniter cuts off the current to the primary coil which induces a spark at the spark plug connected to the secondary coil The igniter will also send an ignition confirmation signal IGF as a fail safe measure to the ECU Component connections 06 M Y in brackets Connector Pin Description ECU Pin ECU Connector 1 Supply Voltage Coil 1 Coil 2 Coil 3 Coil 4 2 Ignition Coil Feedback 22 F3...

Page 171: ...U Connector 1 Signal 15 A3 52 Way Left 2 Ground 41 F4 52 Way Left 06 M Y in brackets 3 Heater Supply 1 K3 52 Way Left 4 Battery Voltage Post catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Signal 3 B3 52 Way Left 2 Ground 29 F4 52 Way Left 06 M Y in brackets 3 Heater Supply 27 H3 52 Way Left 4 Battery Voltage Malfunction Criteria Closed loop fuel control enabled Coolant...

Page 172: ...eriod of time Sensor component connections Vapour Pressure sensor Connector Pins Description ECU Pin ECU Connector 1 Ground 78 L4 28 Way Left 2 Signal 75 C1 28 Way Left 06 M Y in brackets 3 5V V Ref 55 M4 28 Way Left Purge Canister Closure Valve Connector Pins Description ECU Pin ECU Connector A Battery Voltage B ECU ground 9 H2 52 Way Left 06 M Y in brackets Purge Solenoid Connector Pins Descript...

Page 173: ...ap not fitted correctly Canister Closure valve not fully closing P0455 This code is set if during the evaporative leak check the system fails to reach the evacuation target pressure The system will perform additional purge checks to determine the nature of the problem The additional purge checks will also run if the leak check fails to complete because the calculated vapour concentration is above ...

Page 174: ...This code can be caused by the canister closure valve CCV being either stuck closed or open CCV stuck open A CCV is stuck open then there will be minimal tank depression when the leak test is performed Addition check will be performed when the vehicle is being driven before the code is set CCV stuck closed Detection of a stuck closed CCV is implemented by detecting an excessively low tank pressure...

Page 175: ...vel V ref 55 M4 28 Way Left Enable Criteria P0462 P0463 Condition not met as above P0461 Checks for three conditions stuck when full stuck when empty or stuck midway The ECU determines if the sensor is stuck by calculating the amount of fuel used during the test period with the engine conditions as listed below RPM 2800rpm Load 40 Minimum Fuel level 2 litres 0 5 US gallons If the ECU calculates th...

Page 176: ...nsor Connector Description ECU Pin ECU Connector 2 ACCM 2 Relay 1 67 J2 28 Way Left 06 M Y in brackets 3 ACCM 2 Relay 2 60 J3 28 Way Left ACCM A C Control Module Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes A C Control Module failure ECU output circuit failure Notes No MIL will be illuminated for this failure ...

Page 177: ...trol Unit Description ECU Pin ECU Connector 3 Wheel Speed 3 from ABS LR 77 B4 28 Way Left 06 M Y in brackets Sensor characteristics Hall Effect sensor Malfunction Criteria TPS 0 8 Engine speed 1800rpm and 5010rpm Baro 756 mbar Monitor Continuous Potential failure modes Open or short in vehicle speed sensor circuit Build up of debris in the sensing plate on the wheel hub Notes The MIL will be illum...

Page 178: ... idle speed Component connections prior to 06 M Y Connector Description ECU Pin ECU Connector 1 Idle air control value 35 52 Way 2 Battery Voltage 3 Ground Malfunction Criteria P0506 This code is set if the engine fails to achieve the desired idle speed by more than 100 rpm P0507 This code is set if the engine fails to achieve the desired idle speed by more than 200 rpm P0508 This is set when the ...

Page 179: ...Low P0563 System Voltage High Monitor Continuous Enable Criteria Engine running P0562 Voltage Too Low 10V P0563 Voltage Too High 16V Disable Criteria None Potential failure modes Alternator fault Battery fault Notes The MIL will be illuminated if the fault is present for 2 consecutive trips ...

Page 180: ...e checksum for calibration data is the same as checksum saved on power down P0606 checks the watchdog timer after a defined period to see if it has reset If the watchdog timer has not reset then the code has entered an unplanned loop or condition stopping it resetting the timer Monitor P0601 at ECU power up P0606 continuously while the engine running Notes The MIL will be illuminated if the fault ...

Page 181: ...sure sensor Component connections Connector Description ECU Pin ECU Connector 4 RMC 1 MFRU Inertia Switch Pin 1 2 RMC 2 MFRU Fuel Pump Relay 68 J4 28 Way Left 06 M Y in brackets MFRU Multi Function Relay Unit Monitor Continuous Enable Criteria Ignition on Disable Criteria None Potential failure modes Pump open circuit or short to ground Multi Function Relay Unit failure Pump failure ECU output cir...

Page 182: ...cription ECU Pin ECU Connector 5 ACCM 2 AC Clutch Relay 53 J1 28 Way Left 06 M Y in brackets ACCM A C Control Module Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes A C compressor clutch open circuit or short to ground A C Control Module failure A C compressor clutch failure ECU output circuit failure Notes No MIL will be illuminated for this failure...

Page 183: ...ercentage the engine emission output levels can exceed the allowed limits this will produce the fault code P1301 If the misfire percentage is high enough and there is a possibility that the catalyst may be damaged then code P1302 will be set See misfire faults P0300 P0301 P0302 P0303 P0304 Notes The MIL will flash for a 1302 fault code The MIL will be illuminated if the 1301 fault is present for 2...

Page 184: ...as been turned off if the enable criteria are matched Component connections Connector Description ECU Pin ECU Connector 2 RMC 1 MFRU Fuse box 5 RMC 2 MFRU Recirc Pump Relay 69 K1 28 Way Left 06 M Y in brackets MFRU Multi Function Relay Unit Monitor Continuous Enable Criteria P2602 engine not running P2603 engine running Disable Criteria None Potential failure modes Pump open circuit or short to gr...

Page 185: ...rocker arm locking pin into engagement to activate the high speed cam profile A signal from the VVL oil pressure switch provides feedback to the ECU that VVL activation has taken place VVL activation to the high lift camshaft profile occurs at 6200rpm when engine speed is increasing and returns to the low lift camshaft profile at 6000rpm when the engine speed is decreasing Coolant temperature must...

Page 186: ...mming ECU Operating instructions are provided with the tool Important Note The power supply transformer is used for overnight charging of the printer and also for powering the Scan tool during software downloading from a PC personal computer For the software download operation the Scan tool requires a power supply from the mains via the transformer and an inverter Two types of inverter have been u...

Page 187: ...to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c With later type adaptor Connect to COM port on PC Power supply transformer Power supply adaptor em192f T000T1436F 3 Charging printer Power supply transformer Do NOT use adaptor lead for this application Printer em192b ...

Page 188: ...ion of the laptop computer for installation of the Lotus TechCentre is as fol lows Processer 1 70 Ghz 1 GB RAM 40 GB HDD CDRW DVD ROM WIN XP PRO or VISTA USB interface Ethernet or Wireless LAN Note that this laptop should be dedicated soley to the Lotus TechCentre with no other software installed This diagnostic software is designed primarily for use by trained Lotus technicians and is available a...

Page 189: ...Page 46 Lotus Service Notes Section EMP ...

Page 190: ...l injector 6 Knock sensor 7 Oil control valve for variable valve timing 8 Crankshaft position sensor 9 Plug top coil 10 Coolant temperature sensor 11 Pre catalyst oxygen sensor 12 Post catalyst oxygen sensor 13 Oil pressure switch 14 Throttle position sensor 15 Vacuum solenoid for intake flap valve 16 Mass airflow sensor 17 Idle Air Control IAC valve prior 06 M Y For component replacement procedur...

Page 191: ... stop screw to allow the throttle but terfly valve to fully close and introduce clearance between the screw and quadrant stop bracket Screw upwards until contact is just made and then a further turn upwards Secure with the locknut Recheck cable adjustment as above 4 Adjust the throttle pedal downstop such that vigorous full depression of the pedal achieves full opening of the throttle butterfly wi...

Page 192: ...ontained within the ECU Similarly two streams of engine throttle valve positional information are fed back into these processors which are then compared by the ECU software Any discrepancies are analysed and appropriate safety oriented commands outputed to the throttle valve which may be limited to a maximum 15 opening or to a 7 mechanically sprung setting for limp home or in extreme cases the inj...

Page 193: ...n 51 P2102 Throttle Actuator Control Motor Circuit Low 51 P2103 Throttle Actuator Control Motor Circuit High 51 P2104 Throttle Actuator Control System Forced Idle 51 P2105 Throttle Actuator Control System Forced Engine Shutdown 52 P2106 Throttle Actuator Control System Forced Limited Power 52 P2107 Throttle Actuator Control Module Processor 52 P2108 Throttle Actuator Control Module Performance 53 ...

Page 194: ...kshaft Camshaft alignment Throttle Position Sensor B Circuit Low P0222 Description Two potentiometers are built into the throttle valve actuator unit in order to provide a throttle position signal to the ECU Note that the sensors operate on 5 volts Enable Criteria None Disable Criteria None Potential failure modes Signal short circuit 0 283 V Reference voltage open circuit Reference voltage short ...

Page 195: ...grammed Throttle Actuator Control Range Performance P0638 Description The single throttle butterfly valve mounted at the inlet to the intake plenum is operated by a stepper motor under the command of the engine ECU The valve moves through a range of nearly 90 and should display 100 at full throttle and around 2 at idle Monitor Continuous Enable Criteria Engine running Disable Criteria Electronic t...

Page 196: ...onitor Continuous Enable Criteria None Disable Criteria None Potential failure modes Throttle actuator control motor short to supply voltage Throttle Actuator Control System Forced Idle P2104 Description If a problem is detected which could result in faster engine speed than commanded by the pedal the actuator is switched out allowing the throttle valve to default to a 6 mechanically sprung settin...

Page 197: ...ottle Actuator Control System Forced Limited Power P2106 Description If a problem is detected which could result in engine speed control difficulties the ECU will limit throttle opening to a maximum of 15 Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes Electronic throttle fault Note This code indicates action taken by the ECU and will always be accom...

Page 198: ...Disable Criteria None Potential failure modes Signal short circuit 0 283 V Reference voltage open circuit Reference voltage short to ground Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Pedal Position Sensor D Circuit High P2123 Enable Criteria None Disable Criteria None Pote...

Page 199: ...e Disable Criteria None Potential failure modes Signal open circuit 4 487 V Reference voltage open circuit Reference voltage short to ground Sensor failure Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied Throttle Position Sensor A B Voltage Correlation P2135 Description Two potentiometers are...

Page 200: ...Criteria None Disable Criteria None Potential failure modes PPS1 reading incorrectly PPS2 reading incorrectly Notes A maximum throttle opening of 15 may be imposed Throttle Actuator Control System High Airflow Detected P2173 Description The mass air flow is compared with the throttle position to determine whether an incorrect correlation exists Enable Criteria None Disable Criteria MAF fault s pre...

Page 201: ...18 Engine Coolant Temperature Circuit High P0122 Throttle Position Sensor A Circuit Low P0123 Throttle Position Sensor A Circuit High P0131 O2 Sensor Circuit Low Voltage Pre Catalyst P0132 O2 Sensor Circuit High Voltage Pre Catalyst P0133 O2 Sensor Circuit Slow Response Pre Catalyst P0134 O2 Sensor Circuit No Activity Detected Pre Catalyst P0135 O2 Sensor Heater Circuit Pre Catalyst P0137 O2 Senso...

Page 202: ...IL P0601 Watchdog P0606 Checksum P0610 Variant Code not Programmed P0616 Starter Relay Circuit Low Non MIL P0617 Starter Relay Circuit High Non MIL P0628 Fuel Pump Control Circuit Low P0629 Fuel Pump Control Circuit High P0630 VIN not Programmed or Incompatible P0638 Throttle Control Error P0661 Intake Manifold Tuning Valve Control Circuit Low P0662 Intake Manifold Tuning Valve Control Circuit Hig...

Page 203: ...Stuck Off P2647 A Rocker Arm Actuator System Stuck On P2648 A Rocker Arm Actuator Control Circuit Low P2649 A Rocker Arm Actuator Control Circuit High U0115 Lost communication with ECM PCM B Valvematic controller Note Fault code P1047 If the power supply to the VALVEMATIC controller is lost during normal vehicle operation code P1047 will be stored and a limphome mode initiated This will result in ...

Page 204: ... Lotus Service Notes Section EMP Page 61 ...

Page 205: ...Page 62 Lotus Service Notes Section EMP ...

Page 206: ...FJ 1 2 Gearchange Mechanism FJ 2 6 Lubrication FJ 3 13 Driveshafts FJ 4 14 Transmission Replacement FJ 5 17 Transmission Overhaul Special Tools FJ 6 18 See also Toyota transmission repair manual 1ZZ 2ZZ C64 C56 repair manual E120T0327J 1ZR EC60 repair manual CD T000T1523F Updated 17th May 2010 ...

Page 207: ...re designated correspondingly C56 C64 and EC60 C series 5 or 6 no of gears 6 4 or 0 ratio set Publication E120T0327J covers the repair of the C56 and C60 with CD T000T1523F covering the EC60 Two control cables running along the centre of the cabin and beneath the power unit are used to transmit the movement of the gearchange lever to the transmission selector mechanism C56 Five Speed reverse idler...

Page 208: ...reverse idler omitted for clarity 6 5 4 3 2 R 1 Input shaft Output shaft Clutch Diff housing End cover Gearbox Centre support casing bearing f145 EC60 Six Speed Reverse idler 6 5 4 3 2 R 1 Input shaft Output shaft Clutch Diff housing Gearbox casing f146 ...

Page 209: ... in put shaft and that for 1st 2nd on the output shaft with the latter also providing the reverse gear driven pinion incorporated on its periphery A reverse gear idler pinion is mounted on its own stub shaft and may be slid into engagement with both a gear integral with the input shaft and the ring gear on the 1st 2nd synchroniser The housing for the final drive and differential is shared between ...

Page 210: ...om the drive pinions which are being driven from the roadwheels via the output shaft Before the outer sleeve of the synchroniser may be slid on its axial splines to engage with the spline ring integral with 3rd drive gear the speeds of the two parts must be commonised For this purpose a baulk or synchroniser ring is fitted between the two parts being rotationally driven by the synchroniser hub and...

Page 211: ... cross shaft in conjunction with on 6 speed versions a lift collar below the gear lever knob and on 5 speeders a mechanism allowing selection of reverse gear only on approach from the central neutral position Differential Standard cars use a conventional open two bevel gear differential contained in a carrier to which is bolted the final drive output gear and which is supported in two taper roller...

Page 212: ...ith the transmission one cable shift to transmit the fore aft movement of the lever and a second crossgate cable for the sideways movement The gearchange lever is pivotted at its base and operates the shift cable directly via a ball joint half way up the lever The base of the lever has an extended ball pin on the right hand side which engages with a crossgate bellcrank lever the other leg of which...

Page 213: ...n service it may be necessary to make minor adjustments via the threaded ball joint at the front of the cable in order to accommodate lever movement within the shroud aperture From May 07 6 speed In order to ensure smooth selection of 1st 2nd gears it is important to set the crossgate cable adjustment in relation to the reverse inhibitor block Push the lever to the left to abut against the reverse...

Page 214: ...ngle screw each side of the shroud and withdraw the shroud over the gear and parking brake levers Remove the engine bay undertray At the front end of the cables unclip the inner cable ball joint sockets from the ball pins on the mechanism levers Release the outer cable plastic abutment block from the mounting frame At the rear end of the cables remove the R clips retaining the inner cable eyes to ...

Page 215: ... May 07 Gear Lever Inertia weight Shift cable Crossgate cable Lift tube Transmission abutment bracket Lift tube adaptor Reverse selector cable 6 speed only Fixing to p l 40 5 m t x seat front Reverse gate crossmember stop arm Gear lever mounting frame Fixing to seat rear crossmember ...

Page 216: ...rews gentle heat may help to soften the thread adhesive Prise off the spring clip from the top of the lift tube adaptor 2 Release the two grub screws in the underside of the parking brake lever sleeve and withdraw the sleeve 3 Remove the two screws securing the front of the gear lever shroud and carefully withdraw the gear park brake shroud disconnecting the window switch and hazard lamps switch i...

Page 217: ...he gear lever feeding the crossgate ball into the bellcrank lever and position the lever upright Using a suitable screwdriver or pry bar push the base of the lever over to the right to engage the crossgate ball into the plastic socket should click home 10 Remove the G clamp and guide tool and push the crossgate socket to the left to engage the D feature on the gearlever pivot ball with the matchin...

Page 218: ...correct oil level and the oil renewed at intervals specified in the Maintenance Schedule Transmission oil viscosity SAE 75W 90 Specification API GL 4 or GL 5 Quantity 6 speed C64 2 3 litres 6 speed EC60 2 4 litres 5 speed 1 9 litres To check the oil level Remove the engine bay undertray Wipe clean the area around the socket headed level plug on the front face of the transmission main casing Remove...

Page 219: ... the RH side outboard C V joint and gaiter Replacement inboard joints include the inner C V joint and gaiter kit with the C64 type extended stub shaft of the RH joint also including the support bearing and mounting bracket The joints themselves are packed with grease on initial assembly and are maintenance free It is however vitally important that the protective gaiters are carefully inspected at ...

Page 220: ...ying a shock pull to the C V joint body using a slide hammer with a forked end CAUTION Do NOT attempt to remove the inboard C V joint from the transmission by pulling on the driveshaft The balls of the inboard joint are restrained for transit purposes only by a circlip at the end of the ball tracks Applying an extension force to the joint will damage the balls and require joint replacement Apply p...

Page 221: ... cage window any cracking or damage to the cage or pitting galling or chips in raceways call for joint replacement If the joint is found to be serviceable it must be repacked with the special grease provided Pack the grease into the joint itself and also into the inside of the new gaiter NOTE The grease provided in the kits is specially formulated for wear resistance and durability DO NOT use subs...

Page 222: ... illus tration 8 Press the inboard dust shield onto the end of the shaft to the dimension shown in the illustration 9 Refit the driveshaft to the car see above FJ 5 TRANSMISSION REPLACEMENT The transmission may be removed from below after removing the left hand rear suspension assembly both driveshaft assemblies and the exhaust system Release the clutch release fork gearchange cables earth braid a...

Page 223: ...nsmission a CD under part number T000T1523F is available choose Repair Manual Transmission scroll down to find EC60 MANUAL TRANSAXLE in left hand column When applicable select 2010 01 Clutch housing to engine fixings viewed from gearbox side 2ZZ shown M12x55 flange head bolts to block 64 Nm M10x65 bolts also secure M10x55 bolts to starter motor 37 Nm block 37 Nm f134 M10x30 bolts to sump 23 Nm ...

Page 224: ...peed driven gear the claws of the tool may require some grinding to allow complete and proper fitment and an anti spreading device is rec ommended to be fitted around the three claws Striking the puller bolt with a hammer in between tightening steps will help shock the gear from its interference fit and engaging two gears to lock the transmission will also aid the process 2 The preload on the diff...

Page 225: ...J note that a different procedure must be used due to the construction of the LSD Instead of fitting only the differential assembly into the transaxle transmission case and then measuring the turning torque directly at the dif ferential LSD versions require that the differential and output shaft be assembled into the casings and the turning torque measured by using a torque wrench 27mm socket on t...

Page 226: ... GH WHEELS TYRES SECTION GH Sub Section Page General Description GH 1 2 Wheels GH 2 2 Tyres GH 3 4 Winter Tyres Snow Chains GH 4 5 Punctured Tyre Emergency Inflator GH 5 6 Tyre Pressure Monitoring System TPMS 08 onwards USA only GH 6 7 ...

Page 227: ... wheel shake it is very important that the radial and lateral run out of the tyres are to the high standard required by Lotus Cars If any difficulty is experienced with replacement tyres refer to the tyre manufacturer The Bridgestone Potenza Yokohama AD07 or Yokohama A048 tyres fitted to the Elise are suitable for all normal weather conditions but are optimised for dry road sports driving The tyre...

Page 228: ...res The bolts have an M12x1 5 thread 60 conical seat and a 10 spline socket head for which a special exten sion tool is supplied with the car A 17 mm a f deep socket and 1 2 inch square drive wrench should be applied to the extension tool with a tightening torque of 105 Nm required Note that on models fitted with early type upgraded 4 piston front brake callipers with 11mm thick disc mounting bell...

Page 229: ...l pointers on the outer tread blocks The tyres should be replaced before being worn to this minimum legal tread depth Note that the Potenza tread pattern is directional so that the tyre must be fitted onto the wheel with regard to which side of the car the wheel is to be fitted A direction of rotation arrow is included in the tyre sidewall markings Tyre type Bridgestone Potenza RE040 Size front 17...

Page 230: ... high level of steering linearity and response and little per formance degradation with the high temperatures which may be reached on track However tyre performance will decrease at low ambient temperatures resulting in reduced levels of grip and an increased susceptibility to damage from impacts If the car is to be used in winter or in cold conditions it is recommended to fit a vehicle set of the...

Page 231: ...ever carry in the passenger compartment As soon as a puncture is suspected the car should be stopped at the first safe opportunity Continued driving on a deflated tyre will cause irreparable damage to the tyre Directions for use of the aerosol Before using carefully read all the instructions on the canister or on any literature accompanying the product The following instructions apply to the use o...

Page 232: ... that the tyre valves include pressure sensors If the emergency tyre inflator aerosol has been used it will be necessary to renew the tyre valve pressure sensor If a fault is indicated after wheel or tyre replacement it is likely that a sensor has been incorrectly fitted or damaged If a tyre valve is renewed or is moved to a different wheel position the TPMS will automatically identify the new con...

Page 233: ...HG Sub Section Page General Description HG 1 2 Steering Wheel HG 2 2 Upper Column Assembly HG 3 5 Intermediate Column HG 4 9 Front Wheel Alignment Rack Gaiters HG 5 9 Rack Pinion Assembly Removal Replacement HG 6 10 Adjustment of Rack Bar Thrust Pad HG 7 12 ...

Page 234: ...lso providing mountings for the steering lock and column switches Break out inserts fitted in the column upper mounting flanges allow for telescoping of the column in a frontal collision The steering rack assembly which provides 2 4 turns from lock to lock at a 15 8 1 ratio is rigidly mounted inside a chassis transverse extrusion behind the top wishbone rear pivots HG 2 STEERING WHEEL Non Airbag T...

Page 235: ... enable alignment to be maintained on re assembly 4 Use a suitable steering wheel puller tool to locate behind the steering wheel boss and bear against the end of the column CAUTION If excessive force is applied to either the wheel or column without an appropriate puller the telescoping mechanism of the outer column may be overridden necessitating column replace ment 5 If necessary unclip the slip...

Page 236: ...olumn Withdraw the wheel hub rotary connector as sembly from the column splines Alternatively for better puller access the steering wheel can first be removed from the hub by releasing the four retaining screws CAUTION If excessive force is applied to either the wheel hub or column without an appropriate puller the telescoping mechanism of the outer column may be overridden necessitating column re...

Page 237: ...sition of the steering wheel which should deviate from the ideal position by less than 5 Final alignment is achieved by asymmetric adjustment of the track rods retaining the overall toe out setting HG 3 UPPER COLUMN ASSEMBLY Mirror image wheel positions h53 Column lower Non airbag steering mounting bracket wheel shown Instrument pack support bracket Break out insert Column support bracket Turn fla...

Page 238: ...t 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 c...

Page 239: ...reak 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 Outer Inner column column assembly lower end 80 1 mm 58 1 mm h52 Inner column upper end 76 1 mm h52a Alloy break out insert Nylon shear pins h48 ...

Page 240: ... necessary remove the ignition switch First remove the steering lock ignition key barrel see above Remove the retaining grub screw and withdraw the switch 6 If necessary remove the steering lock assembly Remove the spline head screw securing the column switch carrier and drill or chisel out the two shear head bolts fixing the lock assembly to the column 7 Remove the pinch bolt securing the upper u...

Page 241: ...ation The intermediate shaft itself uses a splined joint and on early type shafts a lower indexed pinch bolt groove To remove the intermediate column assembly the upper column must first be removed see sub section HG 3 after which the rack pinion shaft pinch bolt may be removed and the column assembly withdrawn Match marking the lower u j to the pinion shaft will aid steering wheel alignment on re...

Page 242: ...rm nut to 30 Nm and set the front wheel align ment as detailed in sub section CI 2 Steering Rack Gaiters The convoluted gaiters sealing each end of the steering rack housing to the track rods should be inspected at service intervals and replaced immediately if found to be torn cracked or otherwise damaged The ingress of dirt or water into the rack housing will cause rapid deterioration of the trac...

Page 243: ...A111H0017 should be fitted Fitment of the wrong plate identified by the number of notches in the vertical edges will result in an incorrect bump steer characteristic and degraded handling The plate is secured to the chassis by a single pop rivet 6 Feed the rack assembly into the chassis crossmember and engage the pinion shaft into the lower u j with the match marks aligned If a new assembly is bei...

Page 244: ...se 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 turn The following information applies to alloy steel tube type steering rack units Athrust pad backed by a coil spring is used to control the preload between the rack bar teeth and the pini...

Page 245: ...ploded View Oil seal Circlip Ball bearing Pinion Thrust pad Locknut Coil spring Threaded plug h59 Sectional View Pinion shaft Oil seal Circlip Thrust pad Ball bearing Locknut Rack bar Threaded plug Pinion Needle roller bearing Coil spring h60 ...

Page 246: ...ake Pad Replacement JJ 5 6 Parking Brake Adjustment JJ 6 9 Brake Discs JJ 7 11 Brake Callipers JJ 8 12 08 M Y Upgrade Option JJ 8A 13 Brake Master Cylinder JJ 9 15 Vacuum Servo JJ 10 16 Pedal Box JJ 11 21 ABS Theory of Operation JJ 12 24 ABS Electro Hydraulic Unit JJ 13 31 Wheel Speed Sensors JJ 14 32 Data Link Connector DLC JJ 15 32 Special Tools JJ 16 33 Lotus Scanner Tool Checking Procedures JJ...

Page 247: ...L LAYOUT Brake pipe Rear brake calliper ABS controller along subframe Fluid Pedal reservoir box Parking brake secondary cable j161a Master Vacuum cylinder servo Parking brake primary cable Brake pipe along sill Parking brake lever Front calliper ...

Page 248: ...l effort will reduce as cold brakes become heated to normal working temperature and the braking efficiency will increase significantly as new discs or pads become bedded in After fitting new brake components maximum braking efficiency will be achieved if for the first few hundred miles needless heavy braking is avoided and the brake pads are allowed to bed in fully before being used to their full ...

Page 249: ...owing ignition switch on and then go out If the lamp remains lit or comes on whilst driving a fault in the ABS is indicated The base brake system will continue to operate normally but without ABS regulation The car can be driven but should be checked and repaired at the earliest opportunity JJ 3 BRAKE FLUID CHECK CHANGE Before checking the brake fluid level ensure that the car is parked on a level...

Page 250: ... applied to the reservoir bleed the system from each calliper bleed nipple in turn until no air bubbles can be seen 2 Connect the Lotus Scan tool and select ABS and follow the brake bleeding instructions Whilst this automatic process is taking place with all 4 calliper nipples open gently cycle the brake pedal up and down whilst keeping the reservoir topped up to move any air bubbles displaced fro...

Page 251: ...p end of the pad backplates and the centre tang beneath the retaining pin Insert the second pad retaining pin into the calliper passing over the lower central anti rattle spring tongue 7 Before driving the car press the brake pedal several times to bring the pads to their correct running position Top up the master cylinder reservoir if necessary to bring the level to the top of the MAX mark 8 Ensu...

Page 252: ...iper be dismantled 5 If refitting the existing brake pads refit each pad in the same position as originally fitted 6 Before fitting new rear pads the calliper piston must be screwed back into the calliper down the parking brake actuation mechanism This operation requires the use of special tool T000T1242 and the removal of the brake disc Remove the single socket head screw retaining the brake disc...

Page 253: ... snap ring seated in the outboard side of the calliper 9 Refit the roadwheels and press the brake pedal several times to set the brake pad position Before switching on the ignition check the fluid level in the reservoir and top up if necessary 10 Ensure the customer is made aware that maximum braking efficiency will be achieved if for the first few hundred miles needless heavy braking is avoided a...

Page 254: ... 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 For the auto adjustment system to function correctly it is essential that each calliper parking brake lever is allowe...

Page 255: ...s mounted in a steel bracket which also houses the gearchange lever and is bolted to the seat mounting crossmember at the front and to the floor rear crossmember The parking brake lever is secured by two bolts fixing the ratchet quadrant to the bracket Access to the lever is available after removing the cockpit centre trim panel LH lower wishbone front pivot bracket Horseshoe compensator Parking b...

Page 256: ...sion 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 exac erbated by operation in dusty or unmetalled road...

Page 257: ...de bush to the hub carrier c Remove the hex head bolt securing the top guide bush to the hub carrier and withdraw the calliper from the car with the brake hose still connected d Slide out the lower steel guide sleeve and withdraw the bush boot from the calliper Pull the boots off the top steel guide bush and slide out the bush from the calliper e Clean the guide bores in the calliper body with bra...

Page 258: ...f incorrect fitment both front and rear wheels are secured with the longer bolts with no coded security bolts fitted Note that these bolts use the standard spline type socket heads but have a reduced outside diameter of the head Standard bolt B117G6000F 26mm thread length Head outside diameter 22mm Long bolt C117G6000F 28mm thread length Head outside diameter 19mm Braided hoses The steel braided f...

Page 259: ...rnal Curved internal Curved internal vanes cross vanes cross vanes cross vanes cross drilled drilled drilled drilled Common RH LH Handed RH LH Handed RH LH Handed RH LH Single piece Separate 11mm Single piece Separate 8mm thick alloy thick alloy mounting bell mounting bell Wheelbolts 26mm long 28mm long 26mm long 26mm long coded bolt coded bolt coded bolt Brake pad bedding in Fast Road brakes shou...

Page 260: ...er and plug all hoses Disconnect the electrical cables from the reservoir cap cut the tie wrap and withdraw the reservoir from the mounting bracket 4 Release the two brake pipes from the master cylinder and plug the pipes and ports 5 Release the two nuts securing the master cylinder to the brake servo and remove the cylinder 6 Refit the master cylinder in reverse order to removal using NEW locknut...

Page 261: ...wherein a flexible diaphragm divides the space inside a steel shell into two chambers The front chamber is connected via a non return valve to the vacuum produced in the engine s inlet plenum chamber When the brakes are off this vacuum is also applied to the rear side of the diaphragm which is held towards the rear of the shell by a spring The brake pedal is connected to the brake servo control ro...

Page 262: ...ake pedal causes the input rod to move to the right and allows the control valve under the action of its spring to close off the vacuum port in the driving piston The atmospheric port remains closed 147b Driving piston Vacuum port closed off Brake pedal input Atomospheric port closed ...

Page 263: ...em once again in equilibrium From this position of equilibrium further pressure on the pedal will tend to open the atmospheric port and allow pressure in the left hand chamber to increase and move the driving piston to the right before again stabilising Any reduction in pedal pressure will tend to open the vacuum port and allow the higher pressure in the left hand chamber to bleed off into the rig...

Page 264: ...the driving piston will open and bleed the higher pressure from the left side of the diaphragm into the right hand chamber and thence into the engine plenum collapsing the pressure differential across the diaphragm The driving piston is moved fully to the left by the main spring The pliant reaction disc fitted between the input and output rods ensures a graduated application of servo assistance an...

Page 265: ...ased and is not pre loaded by mal adjustment of the input pushrod See sub section JJ 11 Stop light switch The stop switch is mounted in a right angle bracket fixed to the underside of the scuttle and abuts directly against the pedal The switch is retained in the bracket by a quarter turn mechanism To Replace Brake Servo Unit 1 Remove the brake master cylinder see sub section JJ 9 2 From within the...

Page 266: ...of the pedal achieves full opening of the throttle butterfly without allowing the cable to be strained An alternative pedal position which may be preferred for heel and toeing may be achieved by replacing the rubber upstop buffer with a M5x15 hex head setscrew with three flat washers beneath the head for a total thickness of around 7mm The cable must then be re adjusted at the engine abutment as a...

Page 267: ... mounting bracket and disassemble the pedals from the shaft taking careful note of spacers and washers 8 On re assembly note that the pivot bushes of the brake pedal and relay lever should be lubricated with Syntheso GLK1 or equivalent Check pedal pushrod and stop switch operation as detailed above Pedal shaft mounting Pedal box plate fixing Throttle Throttle cable cable abutment on scuttle Pedal ...

Page 268: ... releasing the three M8 bolts and nuts securing the unit to the pedal box The throttle pedal upstop is set internally within the electronic housing with a downstop moulded into the housing itself The brake pedal is pulled off by an extension spring anchored to a bracket rivetted to the scuttle beam There is normally a gap of approximately 3mm between the brake pedal and the pedal box upstop flange...

Page 269: ...ndent hydraulic circuits one for the front brakes and one for the rear the hydraulic elements of the control unit are doubled up with no part of the system shared between the two circuits For the pressure hold function four isolation solenoid valves are used one in the hydraulic circuit for each wheel brake The pressure reduction function is achieved by a separate dump solenoid valve in each of th...

Page 270: ...wheel for example is tending to lock i e its deceleration is too rapid with too great a speed differential with the other wheels 2 The connection between the master cylinder and the LH front brake circuit is interrupted by the isolation valve and the rate of slip increase is reduced 3 If the wheel speed continues to depart significantly from vehicle speed the dump valve is energised to reduce pres...

Page 271: ...licated for the rear brake circuit which remains completely independent of the front circuit Normal Braking During normal braking when the wheel speed sensors indicate no imminent wheel locking the ABS is inactive The solenoids are unenergised so that the isolation valves are sprung open and the dump valves sprung closed Hydraulic fluid from the master cylinder enters the modulator via the inlet p...

Page 272: ...anti lock sequence is to isolate that wheel brake circuit from the master cylinder The ECM ener gises the isolator valve solenoid which closes the valve against spring pressure and maintains existing pres sure in the left hand front brake circuit regardless of any increase in pedal pressure Isolation valve energised and closed Pressure trapped in LHF brake line Inlet from master cylinder j149b ...

Page 273: ...fluid into the low pressure accumulator shared with the RH front circuit Very short activation pulses are used to maintain close control of the pressure reduction and to limit the reduction to that required to restore wheel speed Fluid displaced from the wheel brake circuit is stored in the front brake accumulator against spring pressure and is also used to prime the hydraulic pump Isolation valve...

Page 274: ... sensation felt by the driver with the pressure pulsations from the pump damped and quietened by the restriction of the orifice When wheel speed has been restored and the brake pressure is required to increase the isolation valve is momentarily opened to allow master cylinder pump pressure to raise the pressure in the wheel brake circuit in increments If imminent locking is again sensed the isolat...

Page 275: ...he dump valve closed solenoid de energised to seal off the pressure relief circuit The pump will remain running for a short time to help drain any fluid from the accumulator whose piston is returned to its start position under the action of the spring and return the fluid to the master cylinder reservoir Isolation valve de energised and open Output to LHF brake Inlet from master cylinder Pump runs...

Page 276: ...s on the unit with further protection against incorrect connec tion provided by the use of two different brake pipe union sizes M10 x 1 0 and M12 x 1 0 To Remove Electro Hydraulic Unit When removing the unit beware of dripping brake fluid and take appropriate precautions to prevent damage to paintwork 1 Remove the driver s side front access panel radiator outlet louvre and wheelarch liner 2 Switch...

Page 277: ...crews Note that component parts are calibrated specifically for the Lotus Elise Do not use parts from other sources JJ 14 WHEEL SPEED SENSORS A wheel speed sensor is integrated into each of the four hub bearing assemblies and supplies a signal to the ABS control module The module outputs a road speed signal to the engine ECM and also to the instru ment pack for speedometer operation Output from ea...

Page 278: ...rate valve motor activities Read EEPROM contents Read ECU identification Operating instructions are provided with the tool Important Note The power supply transformer is used for overnight charging of the printer and also for powering the Lotus Scan tool during software downloading from a PC personal computer For the software download operation the Scan tool requires a power supply from the mains ...

Page 279: ...Connect to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c 3 Charging printer Power supply transformer Do NOT use adaptor lead for this application Printer With later type adaptor Connect to COM port on PC Power supply transformer Power supply adaptor em192f ...

Page 280: ...ion of the laptop computer for installation of the Lotus TechCentre is as follows Processer 1 70 Ghz 1 GB RAM 40 GB HDD CDRW DVD ROM WIN XP PRO or VISTA USB interface Ethernet or Wireless LAN Note that this laptop should be dedicated soley to the Lotus TechCentre with no other software installed This diagnostic software is designed primarily for use by trained Lotus technicians and is available as...

Page 281: ...ry via the DLC and when powered a blue tell tale on the unit will light Should updated firmware be available for the VCD usually downloaded as part of an online update TechCentre will automatically update the VCD and display a message to confirm The VCD under part number T000T1472F is supplied in a black plastic carry case containing the follow ing VCD 16 Pin Yellow connector lead VCD to Vehicle U...

Page 282: ...15 The Lotus Scan is a hand held electronic scanner tool with an LCD display panel which is able to display any stored trouble codes and sensor readings as well as allowing manual operation of actuators The facilities available include View fault codes wheel speeds valve activities Clear fault codes Generate valve motor activities Read EEPROM contents Read ECU identification Important Notes Whenev...

Page 283: ...ease command FL REL SOL FDBK Front left solenoid release feedback FR HOLD SOL CMD Front right solenoid hold command FR HOLD SOL FDBK Front right solenoid hold feedback FR REL SOL CMD Front right solenoid release command FR REL SOL FDBK Front right solenoid release feedback RL HOLD SOL CMD Rear left solenoid hold command RL HOLD SOL FDBK Rear left solenoid hold feedback RL REL SOL CMD Rear left sol...

Page 284: ...Lotus Service Notes Section JJ Page 39 4 Circuit Diagram 5 Diagnostic Trouble Codes ...

Page 285: ...function C 12 C0080 Rear left outlet solenoid valve circuit malfunction C 12 C0085 Rear left inlet solenoid valve circuit malfunction C 12 C0090 Rear right outlet solenoid valve circuit malfunction C 12 C0095 Rear right inlet solenoid valve circuit malfunction C 12 C0110 Return pump circuit open or shorted C 10 locked or shorted C 10 C0121 Valve relay circuit malfunction C 09 C0161 Brake light swi...

Page 286: ...NG SECTION KH Sub Section Page General Description KH 1 3 Maintenance KH 2 3 Drain Refill Procedure KH 3 4 Radiator Cooling Fan KH 4 5 Radiator Fan Control KH 5 7 Radiator Feed Return Pipes KH 6 8 Water Pump Thermostat See Section EH Oil Coolers KH 7 8 ...

Page 287: ...eturn pipe pipe in sill Heater feed from Header tank back of cylinder head Radiator by pass Recirculation pump Thermostat open Radiator on Radiator return pipe crash in chassis side rail structure Throttle body thermostat Heater matrix k74a in climate chamber Return to thermostat housing Radiator feed pipe in chassis side rail Heater feed from back of cylinder head Header tank Recirculation pump ...

Page 288: ...le panel and connects to the heater matrix mounted in the chassis front climate chamber The heater return circuit is similarly routed along the left hand side of the chassis to join a steel heater return pipe at the back of the cylinder head and running beneath the inlet manifold to the engine side of the thermostat housing In conditions of heat soak after stopping a hot engine the re circulation ...

Page 289: ...at 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 densit...

Page 290: ...ith air conditioning de pressurise the system and recover the refrigerant via the service ports near the evaporator 4 Remove the two radiator outlet air deflector panels release all tie wraps and fixings securing wiring hanesses and pipes to the radiator mounting panel and disconnect the radiator fan harness plugs 5 If the car is fitted with front mounted oil coolers disconnect the feed and return...

Page 291: ...ounting Front mounting spreader plate spreader plate Radiator mounting panel Front Access to this mounting clip available bracket via turn lamp aperture Rear mounting bracket Engine cooling radiator Air conditioning condenser Fan fixing if fitted Cooling fan p105 ...

Page 292: ...ed for a period of 20 minutes to allow heat soak management A coolant re circulation electric pump is mounted below the coolant header tank and is plumbed into the heater supply line When energised the pump circulates coolant through the engine and heater system drawing coolant from the back of the cylinder head and pumping it through the heater matrix to the heater return pipe and back into the t...

Page 293: ... from within the fuel tank bay push the water pipe forwards until obstructed by the crash structure It is recommended that a suitable hole be cut in the flat vertical face of the crash structure adjacent to the fog lamp harness grommet in order to allow the pipe to be withdrawn forwards 5 To refit retrieve the two support foams from inside the chassis rail Fit the grommet into the hole in the chas...

Page 294: ... 80ºC When open oil can by pass the oil cooler circuit but when fully closed all oil is directed from the sandwich plate via a flexible hose within the RH sill panel over the front wheel arch liner to the top connection on the RH oil cooler or joiner union on single oil cooler cars From an outlet union at the bottom front of the cooler or joiner union another hose runs beneath the crash structure ...

Page 295: ... Bleeding When carrying out routine oil changes the oil quantity contained in the twin oil cool ers and associated pipework is not disturbed and is considered perfectly satisfactory for routine maintenance operations In instances of major engine failure where the oil system may be contaminated with metallic debris all oil cooler lines should be thoroughly flushed out and the oil cooler radiators r...

Page 296: ... LJ Page 1 FUEL SYSTEM SECTION LJ ELISE 111R EXIGE 2004 M Y On non USA Sub Section Page General Description LJ 1 3 Fuel Filling LJ 2 3 Precautions LJ 3 4 Fuel Tank LJ 4 5 Fuel Pump Sender Assembly LJ 5 7 Charcoal Canister LJ 6 8 ...

Page 297: ...rge line Vapour management valve Fuel filler neck Fuel rail Tank breather connection Quick fit connector Charcoal canister Fuel feed pipe Roll over valve Filler breather hose Tank breather pipe Purge line to inlet manifold Fuel tank Fuel pump em208c ...

Page 298: ... the top plate of the fuel pump assembly The connecting pipe is routed through a roll over shut off valve mounted by the canister to protect against fuel spillage in case of vehicle inversion The purge port of the canister is routed through a solenoid valve mounted on top of the canister to a port on the inlet manifold The evaporative emissions control system prevents untreated fuel vapour from th...

Page 299: ...a stopped hot engine WARNING i To minimise the risk of fire and personal injury relieve the fuel system pressure before servicing any part of the fuel supply circuit See Fuel Pressure Relief Procedure below ii To reduce the possibility of sparks occurring when a fuel line is disconnected or when fuel vapour is present the negative battery cable should be disconnected before work is commenced iii W...

Page 300: ...fter switching off the ignition Before disconnecting the fuel line carry out the fuel pressure relief procedure detailed in sub section LJ 3 Carry out the fuel pressure relief procedure detailed in sub section LJ 3 Disconnect the battery It is recommended first to release the quick fit connector located to the rear of the coolant header tank Release the retaining clip securing the pipe joint to th...

Page 301: ...ructural part of the chassis and that the car should not be used without the panel fitted 7 Support the tank before removing the two support cradles from the chassis Each cradle uses two bolts at the front end of the bracket and a single bolt at the rear all threading into Rivnuts in the chassis 8 Carefully lower the tank from the chassis 8 Before re fitting the tank ensure that all the clamping p...

Page 302: ... Torque tighten the cradle fixing bolts to 24 Nm 12 Continue the installation in reverse order to removal and ensure that the shear panel is fitted beneath the fuel tank bay before driving the car LJ 5 FUEL PUMP SENDER ASSEMBLY The combined fuel pump gauge sender unit is mounted in the left hand end of the tank top surface A removeable panel is provided in the top of the chassis crossmember in the...

Page 303: ... combustion process Charcoal Canister This is mounted at the right hand front corner of the engine bay via a bracket fixed to the bulkhead Fuel vapour from within the tank and collected from a spigot on the fuel pump sender top plate is routed via a roll over valve to prevent fuel spillage if the car is inverted mounted on the charcoal canister bracket to the canister port labelled tank This port ...

Page 304: ... 3 7 Switches Instruments Driver s Information MP 4 8 Component Location Fuse Ratings MP 5 14 Audio Equipment MP 6 16 Battery Battery Cables Earthing Points MP 7 17 Wiper Mechanism MP 8 20 Harness Routing MP 9 21 Front Lamp Assemblies MP 10 22 2006 M Y Supplement MP 11 25 2008 M Y Supplement incl PFK alarm system MP 12 28 2011 M Y Supplement MP 13 36 Updated 1st June 2010 ...

Page 305: ...de card is not available on receipt of the car enquire with the dealer immediately Engine Immobiliser In order to provide a measure of automatic vehicle security independent of any driver initiative the system will passively immobilise the engine s cranking and running circuits after the first occurring of the following approximate time delays i Four minutes after switching off the ignition ii Two...

Page 306: ... acknowledged by One flash of the hazard warning lamps Extinguishing of the security tell tale If the alarm had been triggered during the last armed period the disarm command will be acknowledged by the hazard lamps flashing 4 times and the buzzer sounding 4 times The security tell tale will then flash a code to indicate the triggering source One pulse flashing door engine cover boot lid or body f...

Page 307: ...obs Two transmitter fobs are provided with the new vehicle If a transmitter is lost or damaged a replacement should be obtained immediately from your dealer and programmed to the vehicle alarm controller using the system owner s unique Personal Identification Number PIN Up to four transmitter fobs can be matched with the alarm system but all fobs must collectively undergo the single programming op...

Page 308: ...ontroller Mounted on top of the scuttle beam at LH extreme end Accessible after removal of fascia top Siren Unit Mounted on front of radiator duct LH extension beneath LHF turn lamp Accessible only after removal of front clamshell Immobiliser Module Mounted on left hand end of cabin rear bulkhead Accessible after removal of rear bulkhead trim panel Microwave Sensor Mounted centrally on cabin rear ...

Page 309: ...y inertia switch to be tripped the doors will automatically be unlocked Notes In the event of a flat vehicle battery the central door locking will not operate The doors can be unlocked from outside only after Elise opening the engine cover and restoring power to the battery by substitution re charging or jumping to a second battery Exige removing the front body passenger side access panel and prov...

Page 310: ...a window press the upper domed end of the switch The electric window lift mechanismuses an electric motor and winder drum driving a steel cable around top and bottom guide pulleys to a lift block The window glass is fixed to the lift block which is guided by a vertical rail The door harnesses to support CDL and electric windows are routed to the scuttle area via a grommet in the A post area ahead ...

Page 311: ...ough the engine ignition system itself draws no current when the engine is stopped a battery drain will occur through other circuits even when auxiliary equipment is not being used For security reasons and to guard against battery drain always remove the key when leaving the car WARNING Do not push or tow the car unless the key is first used to unlock the column and is then left in the lock Never ...

Page 312: ...le e When only a single segment of the fuel gauge bar graph remains representing approximately 5 litres this amber tell tale will flash Refuel at the next opportunity ABS Tell Tale f This amber tell tale should light for about four seconds following ignition switch on and then go out If the lamp remains lit or comes on whilst driving a fault in the ABS is indicated The base brake system will conti...

Page 313: ...er gears A 6000 rpm limit is imposed on a cold engine in order to reduce possible damage from unsympathetic use The use of wide throttle openings and or high rpm before normal running temperature has been reached will result in premature wear and should be avoided Do not run the engine continuously at its maximum speed or allow overspeeding to occur on the overrun by changing down through the gear...

Page 314: ...he radiator cooling outlet grilles in the front body are cleared of snow before driving the car or overheating may occur Odometer An odometer total distance recorder reading is displayed at the bottom left hand corner of the panel and is calibrated in the same units miles or kilometres as is the speedometer Trip Recorder A trip recorder is provided at the top left hand corner of the panel calibrat...

Page 315: ...he turn indicator lamps and the switch tell tale in unison Press a second time to switch off This facility should be used when the vehicle has to be stopped on the highway in abnormal circumstances where a warning to other traffic would be judicious Use of the hazard warning lamps may be subject to local traffic laws with which drivers should familiarise themselves Instrument Illumination A small ...

Page 316: ... down to indicate a left hand turn and up for a right hand turn The switch will be cancelled when the steering wheel is returned to the straight ahead position For convenience when signalling a lane change lightly pressing the switch up or down will allow its return under spring action Windscreen Wiper Washer The steering column right hand lever switch controls the windscreen wiper and washer and ...

Page 317: ... main fusebox is located in the front services compartment on the passenger side and is protected by a plastic cover For access remove the passenger side front body access panel and unclip the fusebox lid Twenty two slots are provided for Littel type fuses which are numbered and coloured according to their am perage rating and may be pulled out from their slots using the fuse extractor tool provid...

Page 318: ...ng the ABS circuit is located beneath the passenger side fascia top adjacent to the positive post A multi function relay unit containing the engine control relay fuel pump relay and starter relay is mounted in the engine bay near the ECU A similar relay unit is mounted in the front services compartment alongside the fusebox and operates the a c compressor and radiator fans Important Note Although ...

Page 319: ... aerial is supplemented by a digital di pole aerial routed in a similar manner Speakers Two speaker cars are fitted with a speaker in each cabin rear corner in a sound deadening full width rear bulkhead trim panel An upgraded audio option uses the same rear speakers in conjunction with a pair of front speakers mounted one in each dash end panel USA cars have the front speakers mounted in the fasci...

Page 320: ...ow and pull off the breather pipe if applicable Release the single screw securing the clamp bracket at the rear base of the battery and manoeuvre the battery from the base retaining shoes at the front and right hand side When lifting out the battery be aware of the considerable weight and take all appropriate precautions to safeguard personal health Refit the battery with its terminals inboard by ...

Page 321: ...o avoid sharp knocks or shocks keeping the battery as upright as possible Beware of the considerable weight of a battery and take necessary precautions against personal injury Check that the electrolyte level is between the upper and lower markers on the battery case and if neces sary add distilled water The recommended bench charge rate is 4 amps When the battery is fully charged 12 8 volts allow...

Page 322: ...ont earth To ECU earth point stud plate To transmission Positive binding housing post on scuttle m191b Positive binding post on scuttle Chassis front earthing point Starter solenoid Battery negative Battery positive m191b Chassis rear earth point Battery cables positive negative posts ...

Page 323: ... screws into the windscreen buttress and the patch of adhesive between the inboard end and the screen gutter Disconnect the harness plug from the motor Disconnect the washer tubing 3 Remove the wiper arm from the spindle and the spindle rubber surround 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 wit...

Page 324: ...ain to run across the dash top picking up on the positive post and supplying the instrument pack and switchgear The harness then runs along the cockpit centre tunnel to the rear of the cabin over the top of the fuel tank bay and through a grommet at the left hand rear corner of the cabin At the left hand front corner of the engine bay one branch continues rearwards through a rear clamshell grommet...

Page 325: ...the machine between 300 and 700mm in front of the LH headlamp and parallel with the two headlamp units using the sight bar or similar device dependent on the machine design to ensure cross car match Use the guides provided on the machine to ensure the correct height and lateral setting 2 Switch on the headlamp dip beams uppermost lamps and check the lateral beam alignment The knee point of the bea...

Page 326: ...e cover is designed to gather refracted light and prevent scatter above the dip beam cut off Certain atmospheric conditions may result in some condensation inside the lamp unit but this should disperse with the lamps in operation and cause no concern The main beam lamp is mounted lowermost as previously and uses a free form reflector and 55W H7U bulb Above that is the projector type dip beam lamp ...

Page 327: ... the lever in both lamps should be turned counterclockwise to mask The lever turns only a few degrees requir ing little force Applying too much force or movement will damage the system Feel for a slight click Front Turn Lamps For access to the front turn indicator bulb the lamp unit must be released from the body Using a suitable stiff rod via an access hole in the outer top corner of the air inta...

Page 328: ... certain unusual circumstances such as loose surfaces deep snow or when rocking the vehicle free from mud it may be desirable temporarily to switch off the traction control An LTC off button is provided on the gear lever shroud and should with the ignition switched on be held pressed for 2 seconds Both the button tell tale and the LTC warning lamp in the instrument panel will light up amber to con...

Page 329: ...dule Battery 16 10A Sidelamps rear fog Battery 17 10A Dip beam LH Battery 18 10A Dip beam RH Battery 19 20A A C comp relay Battery rad fan 2 fast 20 15A Main beam LH Battery 21 15A Main beam RH Battery 22 7 5A CDL Battery m254 MAIN FUSEBOX Fuses Engine Compartment Fuses and relays associated with the engine management system are contained in two 4 position fuse holders located at the front of the ...

Page 330: ...all 6 speed Elise variants for 06 M Y are new rear lamp clusters incorporating LEDs in the annular segments of the lamps The central elements continue to use filament bulbs The non USA Elise also adopts the USA centre high mounted stop lamp CHMSL featuring red LEDs behind a white lens The light emitting diodes are extremely durable and are serviced only by lamp cluster replacement The turn indicat...

Page 331: ...rm and the vehicle owner s 5 digit alarm Personal Identification Number PIN are supplied on plastic tags attached to the key ring of a new vehicle In order to allow replacement transmitter keys to be programmed it is essential that these numbers are recorded and kept safely by the owner with the vehicle documents It is also recommended that the dealer stress this issue to their customers and in th...

Page 332: ...ed and operational variations will occur Allow an undisturbed period of 2 minutes to elapse to restore normal operation When fully armed and after the settling period of 40 seconds has expired the alarm will be triggered by any of the following actions Interruption of the car battery power supply or siren cables Energising the ignition circuit hot wiring Opening a door Opening the engine lid tailg...

Page 333: ...ngaging the retaining tongue and pressing firmly to engage the clip The transmitter should now operate normally Disconnecting the Vehicle Battery In order to prevent the alarm being triggered before disconnecting the vehicle battery ensure that the alarm is disarmed Emergency Disarming Mobilising If the key head transmitters are lost or damaged the alarm system owner s 5 digit PIN may be used to d...

Page 334: ...dure to input the two digits of the feature code after which the tell tale will flash rapidly for 1 second then beep once or twice to indicate the new status of that feature one for ON twice for OFF Selection will alternate each time that feature code is entered Note that within 10 seconds a second feature code or repeat may be selected from this point by entering only the 2 digit code To exit pro...

Page 335: ... intervals no indication of low tyre pressure will be displayed Tyre fitters and service technicians should be made aware that TPMS is fitted and that the tyre valves include pressure sensors If the emergency tyre inflator aerosol has been used it will be necessary to renew the tyre valve pressure sensor If a fault is indicated after wheel or tyre replacement it is likely that a sensor has been in...

Page 336: ...ervicing is carried out at the prescribed intervals TRIP DISTANCE DIGITAL SPEED DISPLAY TIME CLOCK The top left portion of the LCD panel may be cycled through the following displays Trip distance in same units as analogue speedometer Digital road speed in alternative units to those indicated by the analogue instrument either mph or km h Digital time clock if fitted this feature will not be availab...

Page 337: ...traction control desired with the setting shown on the instrument panel LCD in the form SLIP with a possible range between 0 and 9 The display will revert to showing the fuel level after a few seconds For maximum traction control 0 slip turn the knob fully counterclockwise to MAX To reduce traction control to allow up to 9 slip turn the knob progressively clockwise Fully clockwise 0 traction contr...

Page 338: ... above about 6 mph REAR LAMP CLUSTERS A running change to the LED tail lamp clusters will occur shortly after 08 introduction The new B level lamps incorporate features allowing the previously separate radio supression inductor jump harnesses and for USA cars the ballast resistors to be deleted The new lamps are identified by using a grey moulding for the lamp rear body instead of the previous bla...

Page 339: ...arily without affecting the setting Cruise control automatically disengages when the foot or parking brakes are applied a gearchange is made or when the vehicle s speed falls below 30 mph 50 km h To disengage it manually press once the O button Resuming a set speed Caution The resume function should be used only if the driver is aware of and wants to return to the set speed To resume cruising afte...

Page 340: ...s are secured to the main wiring harness just ahead of the scuttle beam and accessible from the passenger footwell Fuse Rating Circuit C1 20A Interior fan C2 15A Wiper motor C3 7 5A Audio key in C4 7 5A A C compressor C5 15A Auxiliary driving lamps C6 5A 1 6 ltr Alternator ign C7 5A 1 6 ltr Alternator sense C8 5A Daytime running lamps SlotRate Circuit 14 20A Rad fans 1 2 slow 1 fast 15 7 5A Radio ...

Page 341: ...ss cover in the wheelarch liner The alignment relationship between high and low beam lamps is fixed but two adjusters are provided on the back of the headlamp housing by which the whole lamp unit may be adjusted To adjust the beam laterally turn the outboard hexagonal adjuster screw Optimum setting is 0 To adjust the beam vertically turn the inboard adjuster screw Optimum setting is 1 2 To replace...

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Page 376: ...ce Notes Section MP 14e ELECTRICS SECTION MR 14e CIRCUIT DIAGRAMS 2011MY ELISE WITH 1ZR POWERTRAIN Contents List Circuit Diagrams 2 Circuit Diagrams 3 47 Fuse Layout 48 Colour Codes Abbreviations 49 Updated 19th May 2010 ...

Page 377: ...el Sensing Clutch Potentiometer C8 21 EMS O2 Sensors C9 22 EMS CVCV C10 23 Cruise Control C11 24 EMS Valvetronic C12 25 Daytime Running Side Lamps Non USA D1A 26 Daytime Running Side Lamps USA D1B 27 Headlamps D2 28 Driving Lamps D3 29 Fog Lamps Non USA D4 30 Direction Indicators Hazard Lamps Non USA D5A 31 Direction Indicators Hazard Lamps USA D5B 32 Brake Lamps Non USA D6A 33 Brake Lamps USA D6B...

Page 378: ...Page 3 Lotus Service Notes 2011MY Elise Circuit Diagrams All Markets Section MP 14e 1ZR Powertrain ...

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Page 401: ...Page 26 Lotus Service Notes 2011MY Elise Circuit Diagrams Non USA Section MP 14e 1ZR Powertrain ...

Page 402: ...Page 27 Lotus Service Notes 2011MY Elise Circuit Diagrams USA Only Section MP 14e 1ZR Powertrain ...

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Page 405: ...Page 30 Lotus Service Notes 2011MY Elise Circuit Diagrams Non USA Section MP 14e 1ZR Powertrain ...

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Page 408: ...Page 33 Lotus Service Notes 2011MY Elise Circuit Diagrams Non USA Section MP 14e 1ZR Powertrain ...

Page 409: ...Page 34 Lotus Service Notes 2011MY Elise Circuit Diagrams USA Only Section MP 14e 1ZR Powertrain ...

Page 410: ...Page 35 Lotus Service Notes 2011MY Elise Circuit Diagrams Non USA Section MP 14e 1ZR Powertrain ...

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Page 418: ...Lotus Service Notes 2011MY Elise Circuit Diagrams Gulf States Section MP 14e 1ZR Powertrain Page 42 ...

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Page 425: ...t Side Marker FTC Fuel Tank Connector GND Ground IP Instrument Pack I P Input LF Left Front LIHC Left Inner Harness Connector LOHC Left Outer Harness Connector LR Left Rear MB Main Beam NPL Number Plate Lamp O2 Oxygen sensor O P Output PDHC Passenger s Door Harness Connector RF Right Front RIHC Right Inner Harness Connector RIL Rear Outer Lamp RMC Rear Module Connector ROHC Right Outer Harness Con...

Page 426: ...OI MAINTENANCE LUBRICATION SECTION OI Page Recommended Lubricants 2 Maintenance Schedule Elise 111R 04 Exige non USA 3 Elise Exige North America 6 Pre Delivery Inspection 9 Body Paint Inspection Elise 11 Exige 12 Licence Plate Fitment 13 ...

Page 427: ...conomy at low temperatures in combination with good wear protection at elevated temperatures and at high engine speeds If Texaco Havoline products are not available an oil meeting the specification below should be used but note that in general lubricants described as synthetic are likely to be only semi or part synthetic Use only oils confirmed as being fully synthetic Note also that no oil additi...

Page 428: ...r as required 3 Inspect brake pads discs 1 000m 1 500 km intervals or as required 4 Thorough safety check including wheels tyres suspension steering and brake systems 5 The Lotus Elise Exige is designed as a road going sports car It is recognised that owners may wish to use the car occasionally on closed circuit tracks to experience the car s full range of dynamic capabilities However use of the c...

Page 429: ... special cndts 18 Inspect brake hoses pipes hydraulic units 19 Check brake fluid level X 20 Renew brake clutch fluid 2 yr Steering Suspension 21 Check security and condition of front rear suspension inc free articulation of rear toe link ball joints 22 Check torque of rear toe link inboard fixing 60 Nm X 23 Inspect dampers for leaks and performance 23a Where applicable Check security of damper res...

Page 430: ...vibration Wheel balance Recommended Service Times After Sales Service 1 9 hr Regular Service 2 8 hr Op 2a 0 6 hr Op 4 0 1 hr Op 5 0 7 hr Op 7 0 6 hr Op 8 0 5 hr Op 9a 0 1 hr Op 9b 0 6 hr Op 9c 0 3 hr Op 15 0 6 hr Op 17a 0 3 hr Op 20 0 6 hr Op 23a 0 2 hr Op 35 0 1 hr General comments Additional Work Performed or Required Work completed by Owner s Maintenance Booklet stamped Dealer Stamp Date ...

Page 431: ... Department Job no Owner s name Vehicle Vehicle registration no V I N Recorded mileage Mileage at last service In order to maintain warranty validation and help ensure proper safety emissions performance and dependability of the vehicle Lotus Cars Ltd requires that the vehicle be serviced in accordance with this schedule Each service should be performed within 7 500 miles or 6 months of the previo...

Page 432: ...ion special cndts 18 Inspect brake hoses pipes hydraulic units 19 Check brake fluid level X 20 Renew brake clutch fluid 2 yr Steering Suspension 21 Check security and condition of front rear suspension inc free articulation of rear toe link ball joints 22 Check torque of rear toe link inboard fixing 60 Nm X 23 Inspect dampers for leaks and performance 23a Where applicable Check security of damper ...

Page 433: ...vibration Wheel balance Recommended Service Times After Sales Service 1 9 hr Regular Service 2 8 hr Op 2a 0 6 hr Op 4 0 1 hr Op 5 0 7 hr Op 7 0 6 hr Op 8 0 5 hr Op 9a 0 1 hr Op 9b 0 6 hr Op 9c 0 3 hr Op 15 0 6 hr Op 17a 0 3 hr Op 20 0 6 hr Op 23a 0 2 hr Op 35 0 1 hr General comments Additional Work Performed or Required Work completed by Owner s Maintenance Booklet stamped Dealer Stamp Date ...

Page 434: ...partment Check security of battery terminals and voltage Below 12 4V recharge Below 11 7V replace Inspect operation of all exterior interior lamps Inspect operation of horn hazard switch Inspect operation of alarm system CDL fuel flap release Inspect wiper operation at all speeds park position Inspect screen washer powerwash operation jet alignment reservoir level Inspect operation of all instrume...

Page 435: ...ranty claims on the particular car being rejected ONCE COMPLETED SEND ORIGINAL COPY OF PDI FORM OWNER S HANDBOOK MAINTENANCE RECORD PAGES P D I REGISTRATION OF SALE AND NEW CAR HANDOVER CHECKLIST LSL486 TO Pre Delivery Inspection Completed by Date Undertake complete vehicle valet Valet Brake performance Additional Work Completed by Road Test Performance Check Add comments as necessary Engine perfo...

Page 436: ...G N SHADING C CHIPS O OVERSPRAY D DISTORTION P PRE RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES H PIN HOLES T THIN PAINT K SINKAGE U M MAT CREASES V VOIDS DATE OF PDI VIN COLOUR OWNER PRE DELIVERY PAINT MARK UP ELISE 2 PAINT DEFECT CODE DIRT UNDER PAINT ...

Page 437: ...NG N SHADING C CHIPS O OVERSPRAY D DISTORTION P PRE RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES H PIN HOLES T THIN PAINT K SINKAGE U M MAT CREASES V VOIDS DATE OF PDI VIN COLOUR OWNER PRE DELIVERY PAINT MARK UP EXIGE PAINT DEFECT CODE DIRT UNDER PAINT ...

Page 438: ...e used Licence Plate Fitment on North American Elise LSL480 Front The Elise front clamshell incorporates a moulded plinth for the front licence plate A licence plate mounting frame is supplied loose with the car for those States which require front plates The aluminium frame has four M6 threaded studs and should be fitted to the clamshell plinth by marking and drilling the four 6mm clearance holes...

Page 439: ...Page 14 Section OI Align edge of paper with end of plinth Top edge of plinth Align edge of paper with end of plinth Mark hole centres and drill to 6mm Bottom edge of plinth ...

Page 440: ...Cooling Fans Re circulation Pump PL 3 11 Refrigerant Handling PL 4 13 Refrigerant Pipework Precautions PL 5 13 Refrigerant Oil PL 6 15 Compressor PL 7 16 Condenser PL 8 18 Receiver Drier PL 9 20 Expansion Valve PL 10 20 Heater Evaporator Fan Unit PL 11 21 Air Distribution Unit PL 12 22 Refrigerant Pipes PL 13 23 Air Blender Re circ Flap Actuators PL 14 23 Updated 9th June 2010 ...

Page 441: ...derail Heater matrix Water return pipe along outside of Water return to LH chassis siderail engine side of thermostat p77c Coolant re circulation pump Refrigerant Circuit Receiver drier Feed return pipes along outside of RH chassis siderail Condenser Expansion valve Compressor Evaporator casing p78c ...

Page 442: ...tioning If fitted Basic Principles The air conditioning unit uses a cycling clutch system with a thermostatic expansion valve to provide refrigerated air to the vehicle interior The system comprises a closed circuit containing refrigerant R134a a compressor mounted on the front side of the engine driven by multi vee belt from the front end of the crankshaft via an electromagnetic clutch a condense...

Page 443: ...r and other parameters allow it i e ignition on blower fan speed selected a c pressure switch closed the a c circuit is activated and the compressor clutch is engaged A thermostat using a sensor inserted into the outlet side of the evaporator finning monitors the temperature of the refrigerated air and signals the compressor to cycle on and off in order to maintain outlet air temperature just abov...

Page 444: ...rts in the front wall of each footwell The fan blower unit directs all airflow through the a c evaporator if fitted after which a pair of linked air blender flaps control the proportion of air which flows through the heater matrix The upper flap is driven by a stepper motor from the cockpit temperature selector with the lower flap linked to the upper by toothed belt After leaving the HVAC chamber ...

Page 445: ... Page 6 Airflow through a c heater unit Cold air Trunking to distribution unit Ambient or re circulated air inlet p110b Heater Fan blower matrix a c evaporator if fitted Warm air Flap in full warm position p110a Butterfly flap open ...

Page 446: ...n the fresh air intake in order to provide a 90 recirculation supply to the blower fan The re circulation facility should be used when maximum refrigeration is desired The tell tale in the switch button lights up green when the circuit is active Heater Temperature With the left hand rotary electrical control turned fully counterclockwise the air blender flaps are posi tioned to direct all the airf...

Page 447: ... flap to close off the wind screen vents and direct all airflow to the four face level vents each of which may be ma nipulated to adjust volume and direction The footwell flap is closed Windscreen Scuttle baffle panel To face level Air distribution unit vents From Chassis scuttle climate chamber Rotary flap Connecting link p102a Footwell flap closed ...

Page 448: ...r motor turns the rotary flap to progressively close off the face level vents A rod connecting the rotary flap to the footwell flap is arranged to open the footwell vents in opposite proportion until at the footwell symbol all airflow is directed to the footwells Footwell flap open From climate chamber Screen footwell ports closed off To footwells p102b ...

Page 449: ...nob fully clockwise and se lect maximum temperature and fan speed On cars with adjustable windscreen vents direct the centre pair of screen vents slightly rear wards and the end pair of vents forwards as shown in the illustration Ventilation Shut Off To close off the ventilation which may be desirable in heavy traffic to reduce the in duction of fumes into the car turn off the fan turn the distrib...

Page 450: ...nto the heater supply line When energised the pump circulates coolant through the engine and heater system drawing coolant from the back of the cylinder head and pumping it through the heater matrix to the heater return pipe and back into the thermostat housing The pump functions only with ignition off in conditions where the ECU remains live The pump is then activated at coolant temperatures over...

Page 451: ...belt mouting frame backstay Outlet from pump to heater Coolant header tank Wiring harness Coolant re circulation pump p109b Heater return hose Heater feed from cylinder head Fans compressor relay module Shelf on driver s side wheelarch liner p108 ...

Page 452: ...FRIGERANT PIPEWORK PRECAUTIONS The following precautions must be observed when carrying out any work on the refrigerant pipework Before disconnecting any refrigerant pipework the refrigerant must first be recovered using suitable 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 flex...

Page 453: ...rinary switch to pipe 1 7 16 20 UNF 1 27 15 20 Nm 10 Clamp plate pipes to expansion valve 1 M6 1 7 9 Nm Use refrigeration oil only smear on o rings and threads prior to assembly Gloves should be worn when handling refrigeration oil see data sheet 10 F 9 C E 1 4 C D 2 B 8 E 2 A 3 D 3 D 7 E 4 5 C E 6 D p75b Key Description Size Part Number A Suction line to compressor 18mm o d A120P6002H B High pres...

Page 454: ...t escapes necessitating the addition of a speci fied quantity of oil to the compressor on re assembly see section PL 7 If a refrigeration component is to be replaced the removed item will contain a certain amount of oil and a corresponding amount of new oil must be added to the system on re assembly Condenser 30 cm Evaporator 30 cm Any major pipe or hose 10 cm Receiver drier 30 cm Compressor 2ZZ 1...

Page 455: ... ports to prevent ingress of dirt and moisture 4 Disconnect the compressor clutch harness 5 Release the three compressor fixing bolts and remove the compressor from the engine Retain the compressor for oil quantity measurement if a new unit is to be fitted Oil Quantity Adjustment Prior to Compressor Refitment Refitting Existing Compressor i If the existing compressor is to be refitted after normal...

Page 456: ... and tighten the fixing screws to 10 Nm 7 lbf ft 3 Connect the compressor clutch harness 4 Recharge the system with R134a refrigerant Compressor harness connector High pressure outlet connection Low pressure suction inlet connection p113 Compressor fixing bolts Note The 1ZR FAE engine used in the 1 6 litre Elise is a variable displacement compressor instead of the cycling clutch type used on the 1...

Page 457: ... two cooling fans For access to the condenser or cooling fans the front clamshell must be removed followed by the radiator mounting panel with the complete cooling pack 1 Remove the front clamshell see sub section BR 6 2 Remove the two air deflector water shields 3 Drain the coolant and disconnect the feed and return hoses from the radiator 4 Unplug the fan harness connector s 5 Recover the refrig...

Page 458: ...ction PL Page 19 Front mounting spreader plate Rear mounting spreader plate Radiator mounting panel Front mounting bracket Rear mounting bracket Engine cooling radiator Air conditioning condenser Fan fixing Cooling fan p105 ...

Page 459: ...tem has been open to at mosphere for any length of time e g fol lowing accident damage or a burst hose or damaged component the receiver drier unit must be renewed and should be the last component to be fitted and uncapped only immediately prior to connection and recharging The receiver drier is clamped to a mounting bracket at the front of the climate chamber If the receiver drier is to be re pla...

Page 460: ... PL 11 HEATER EVAPORATOR FAN UNIT The heater matrix and a c evaporator are contained within a single housing together with the air blender temperature control flaps The housing is mounted in the chassis climate chamber where it is clipped to the fan blower unit and retained by a simple clamp bracket Note that the heater a c blower unit is fitted the opposite way round between Rover and Toyota powe...

Page 461: ...ate chamber Earth cables are connected to chassis negative post at the left hand side of the chamber Rear circuit brake pipe is fitted between master cylinder and bulkhead connector Position the fan housing into the passenger side of the chassis chamber Fit the drain tube into the base of the heater evap unit and use a guide wire or similar to aid routing of the tube through the chassis crossmembe...

Page 462: ...essible with the unit in situ Remove the front clamshell sub section BR 6 release the harnesses from the the front edge of the climate chamber and tie back the harnesses and water hoses to allow optimum access to the actuator Pull off the moulded water shield unclip the actuator outer cover and slide off a drive gear to allow the flap to be moved for access to the two fixing nuts inside the casing...

Page 463: ...Lotus Service Notes Section PL Page 24 Hot air dam Gutter extension panel Radiator inboard fixing sb79 ...

Page 464: ...on QH Page 1 CLUTCH SECTION QH Sub Section Page General Description QH 1 3 Clutch Pedal QH 2 3 Hydraulic Release System QH 3 3 Clutch Assembly QH 4 6 Supplement for 2011 Elise QH 5 9 Updated 9th June 2010 Updated 9th June 2010 ...

Page 465: ... LAYOUT Friction plate Clutch cover Release bearing Bleed nipple Bearing retaining spring Release fork Slave cylinder Fork gaiter Master cylinder Flexible hose Steel pipe Steel pipe Pipe adaptor Hose abutment brackets pl4701mt Updated 9th June 2010 ...

Page 466: ...oke with fluid being returned to the master cylinder reservoir QH 2 CLUTCH PEDAL The clutch pedal is machined from an aluminium alloy extrusion which is common to the brake and throttle pedals with an extruded footpad keyed bonded and rivetted to the bottom of the pedal Synthetic top hat bushes are used to provide maintenance free articulation on the steel pivot shaft with a pair of synthetic bear...

Page 467: ...t and operates the clutch fork by a fixed length pushrod A bleed nipple is provided by which to bleed air from the hydraulic system Mounting bolts Slave cylinder Clutch fork Bleed nipple Steel pipe Hose connection q52 Pedal box Connection to fluid reservoir Clutch master cylinder Mounting bolt Pedal pushrod Clutch pipe q51 connector Updated 9th June 2010 Updated 9th June 2010 ...

Page 468: ...Lithium soap based glycol grease on the piston and seal before carefully inserting the spring and piston into the cylinder Fit the pushrod into the boot and the boot to the cylinder Fit the cylinder with the tie wrap bracket to the clutch housing and torque the two fixing bolts to 12 Nm Fit the hydraulic pipe to the slave cylinder and torque to 15 Nm Bleed the hydraulic system and tighten the blee...

Page 469: ...s as shown overleaf 4 Matchmark the clutch cover to the flywheel before progressively loosening each clutch cover bolt half a turn at a time until clutch cover spring pressure is released Withdraw the cover from the flywheel dowels taking care not to allow the friction plate to drop 5 Pull the release fork off the fork pivot ball and withdraw fork and release bearing from the transmis sion Inspect...

Page 470: ...tting clutch assembly 1 Using a universal type centralising mandrel position the friction plate with the flatter side towards the flywheel and fit the clutch cover onto the flywheel dowels with the match marks aligned if applicable 2 Fit the clutch cover retaining bolts finger tight and monitor friction plate centralisation as the bolts are progressively tightened in a diagonally opposite sequence...

Page 471: ... 8 Clutch housing to engine fixings viewed from gearbox side 2ZZ shown M12x55 flange head bolts to block 64 Nm M10x65 bolts also secure M10x55 bolts to starter motor 37 Nm block 37 Nm f134 M10x30 bolts to sump 23 Nm Updated 9th June 2010 ...

Page 472: ...the transmission input shaft The hydraulic pipe enters the housing from above via a union equipped with a bleed nipple for the expulsion of air from the system Access to the slave cylinder is available only after separation of the engine from the transmission For overhaul and repair procedures refer to CD T000T1523F and select New Car Features 2008 11 Update New Features Clutch Diaphragm spring cl...

Page 473: ... Tale WD 2 3 Data Link Connector WD 3 3 Trouble Codes WD 4 4 Diagnostic Scanner Tools WD 5 4 Safety Precautions Shipping Storage Disposal WD 6 8 Theory of Operation WD 7 11 Sensor Diagnostic Module SDM WD 8 13 Driver Airbag Module WD 9 14 Rotary Connector WD 10 15 Passenger Airbag Module WD 11 16 Seat Belt Pre tensioners WD 12 18 ...

Page 474: ...iated at the same time as the airbags is a pyrotechnic device on each seat belt reel assembly which uses a rack and pinion mechanism in order to apply a tightening force to the belt reel and remove any slack from the belt The force sustained by the belt and its user is then controlled by a torsion bar within the belt reel to limit the deceleration force to which the occupant is subjected Note that...

Page 475: ...ith the old unit WD 5 DIAGNOSTIC SCANNER TOOLS In order to provide for communication with the airbag SDM engine management system ECU and anti lock brake system a hand held electronic scanner Lotus Scan 3 part number T000T1418F may be plugged into the Data Link Connector see earlier Amongst the operations available using the Lotus Scan 3 tool are Reading of Trouble Codes Clearing of Trouble Codes ...

Page 476: ...Connect to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c 3 Charging printer Power supply transformer Do NOT use adaptor lead for this application Printer With later type adaptor Connect to COM port on PC Power supply transformer Power supply adaptor em192f ...

Page 477: ...ion of the laptop computer for installation of the Lotus TechCentre is as follows Processer 1 70 Ghz 1 GB RAM 40 GB HDD CDRW DVD ROM WIN XP PRO or VISTA USB interface Ethernet or Wireless LAN Note that this laptop should be dedicated soley to the Lotus TechCentre with no other software installed This diagnostic software is designed primarily for use by trained Lotus technicians and is available as...

Page 478: ...ry via the DLC and when powered a blue tell tale on the unit will light Should updated firmware be available for the VCD usually downloaded as part of an online update TechCentre will automatically update the VCD and display a message to confirm The VCD under part number T000T1472F is supplied in a black plastic carry case containing the follow ing VCD 16 Pin Yellow connector lead VCD to Vehicle U...

Page 479: ...eam Never use an SDM from another vehicle or modify its mounting to the Elise Exige WARNING Handle the SDM with great care Never strike or jar the SDM as this could cause airbag deploy ment and result in personal injury or improper operation of the SRS All module and mounting bracket bolts must be correctly installed and tightened to assure proper security and operation Never power up the SRS when...

Page 480: ...ave live undeployed inflator modules may have to be scrapped because they have completed their useful life or have been severely damaged in a non deployment type accident The following procedure should be followed when scrapping a vehicle with an undeployed module 1 Follow the safety procedure detailed in sub section WD 6 to turn off the ignition disconnect the battery and unplug the yellow 4 way ...

Page 481: ... as shown Make sure the power supply is turned off and is situated the length of the detona tion wires away from the airbag Only detonate ONE at a time Ensure the detonation wires are discon nected from the power supply Place 1 airbag into the explosion con tainer and connect the detonation wires Do not snag wires Secure lid with sandbags Put on your Eye Ear protection Connect the detonation wires...

Page 482: ...following Sensor Diagnostic Module SDM Driver airbag module Passenger airbag module Rotary connector Seat belt pre tensioners Sensor Diagnostic Module SDM The SDM is the main electronic control unit ECU of the SRS whose function is to detect rates of forward deceleration and when interpreted as a collision accident requiring supplementary occupant protection the SDM triggers as a single set the dr...

Page 483: ...ts requiring four consecutive incidents for a trouble code to be set the present condition and fault display will be activated already after two consecutive events if the related trouble code has already been stored in a previous operating cycle Faults concerning the voltage supply overvoltage undervoltage will lead to tell tale activation only until the regular voltage range has been reached agai...

Page 484: ...ty procedure detailed in sub section WD 6 to turn off the ignition disconnect the battery and unplug the yellow 4 way connector to the inflator module alongside the steering column 2 Column shrouds Remove the two screws retaining the top part of the shroud and the four screws retaining the lower part and withdraw both parts from the column 3 Instrument shroud Pull the instrument shroud backwards t...

Page 485: ...r within the SDM current flows through the deployment loop of both the driver and passenger airbag module initiators and ignites the gas generating material Each bag inflates in a fraction of a second the driver s bag bursting open the steering wheel centre trim cover and then deflates via vents in the bag with the whole cycle taking less than one second The airbag is designed for a single deploym...

Page 486: ...uttons output from the horn buttons The steering column side of the device is fitted with a 4 way connector block which plugs into the SRS harness The steering wheel side of the device has two 2 way connector plugs one for the airbag module and one for the horn buttons The coil housing is constructed in two parts with the outer part fixed to the outer stationary column and the inner part keyed to ...

Page 487: ...and fit the airbag module into the steering wheel Retain with the two socket head screws and tighten to 7Nm 10 Refit the column shrouds and when all service work is complete mate the horn airbag connector to the vehicle harness clipping the connector to the column and reconnect the battery Check that the airbag tell tale lights for a few seconds with ignition and then goes out WD 11 PASSENGER AIRB...

Page 488: ...over are pointed away from you In case of an accidental deployment the bag will then deploy with minimal chance of injury When placing a live airbag module on a bench or other surface always face the bag and trim cover upwards away from the surface This is necessary so that a free space is provided to allow the airbag to expand in the unlikely event of accidental deployment 5 If an airbag deployme...

Page 489: ...e tensioner triggering conditions apply the SDM signals ignition of the gas generator the pressure from which forces the piston and toothed rack downwards causing rotation of the pinion gear and a re winding of the seat belt webbing The force sustained by the belt and its user is then controlled by a torsion bar within the belt reel to limit the deceleration force to which the occupant is subjecte...

Page 490: ...withdraw the belt reel assembly and spacer block Fitment of Seat Belt Assembly WARNING Before removing or refitting a pyrotechnic seat belt assembly the ignition key should be withdrawn and the battery leads disconnected from both positive and negative terminals and iso lated to ensure that accidental contact cannot occur Each seat belt reel assembly is secured via a spacer block to the seat belt ...

Page 491: ...fuel of the gas generator not burned during ignition is slightly flammable The unit there fore must never be disassembled damaged or the parts manipulated Any advertising or demonstrations of the pre tensioner assembly should only be carried out using inert pre tensioners without the pyrotechnic charge The base of the pre tensioner must be painted green with visible and indelible wording stating I...

Page 492: ...ian General notice Storage transport dismantling and or recycling of the pre tensioner shall be carried out according to the legal and local regulations taking account also of directives for masonry fire fighting transport environmental protection and the safety and health of all staff WARNING The seat belt pre tensioner devices fitted on the Lotus Elise are designed and calibrated specifically fo...

Page 493: ... Exige S C 2 Technical Data Exige S C TD 3 Body Exige S C B 4 Front Suspension Exige S C C 5 Rear Suspension Exige S C D 5 Engine Exige S C E 5 Wheels Tyres Exige S C G 11 Brakes Exige S C J 11 Cooling Exige S C K 11 Maintenance Lubrication Exige S C O 12 Clutch Exige S C Q 12 Miscellaneous Exige S C Z 12 ...

Page 494: ...ed with a simplified specification The performance of the standard Exige is uprated by the fitment of a Magnuson supercharger belt driven from the crankshaft feeding through an air air chargecooler into a new plenum intake manifold and featuring a supercharger integral by pass valve The 240R engine uses a mechanical throttle and a 5th injector mounted in the intake manifold plenum whereas the 06 M Y ...

Page 495: ... l 137 4 PS l Lubrication system supplement 240R Cup Accusump oil storage reservoir Oil cooling Twin front mounted oil coolers Wheels Tyres Wheels type 240R Lightweight forged alloy 5 spoke satin black or high power silver size front 240R 7J x 16 rear 240R 8J x 17 Suspension Ride height mid laden front rear 240R Cup 120 120 2 x 75 kg pass tank fuel Spring rate front 240R Cup 325 lb in rear 240R Cu...

Page 496: ...ith an enlargement funnel mouth without grille for increased airflow and enhanced chargecooler efficiency Interior Each Lotus Sport Exige 240R is individually numbered from 001 to 050 and identified by a Lotus Sport build plate styled after those used by Team Lotus for the Formula One cars The plate is riveted to the chassis main side rail on the passenger side and is engraved with the unique Limited...

Page 497: ...nd 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements On 240R models the gas reservoirs are mounted on the roll over bar backstays and on Cup cars on the toe links Each reservoir is connected to its damper body by a steel braided hose Compression bump damping is adjusted by turning the knob on the end of the gas reservoir canister Turn clockwise to incr...

Page 498: ...oler inlet duct Supercharger outlet connector Supercharger outlet elbow Supercharger outlet adaptor Mounting lug for supercharger Fixing point Swan neck Chargecooler to manifold adaptor fixings outlet duct supercharger inlet Fixed to engine mounting plinth By pass valve capsule pl4207ls pl4209lr Strut to clutch Alternator anchor slave cylinder mounting ...

Page 499: ... to inlet manifold and cam cover Bracket to inlet manifold Fixing to inlet manifold Rubber mounting Chargecooler outlet duct Inlet manifold Chargecooler Chargecooler inlet duct Boss for 5th injector Standard 240R airbox Supercharger outlet elbow Supercharger outlet adaptor Electronic Supercharger throttle body FRONT Throttle body adaptor le2047a pl4610mx ...

Page 500: ...the front of the engine bay with the connecting hose routed over the RH rear wheelarch The device comprises an alloy cylinder divided by a sliding piston one side of which is connected to the engine oil supply with the other containing pressurised air With the engine running the cylinder is charged with oil provided by the engine oil pump but if the pressure should drop for a short period due to o...

Page 501: ...t to maintain oil at this level to accommodate the oil transfer into the Accusump at pressures greater than 40 psi Be aware that checking the oil level under any conditions other than 15 psi pre charge and 40 psi oil pressure will produce inconsistent results Oil Changing Before draining the sump the ignition should first be switched on to open the EPC valve and allow the Accusump to discharge the ...

Page 502: ...e fixing located inside the adaptor Permabond should be applied over the entire thread length Orientate the adaptor with the outlet pointing towards the rear of the car when fitted Torque tighten all fixings to 25 Nm Clean mating faces of outlet adaptor and outlet elbow using Betaclean 3900 Fit O ring into groove in outlet adaptor face Fit outlet elbow to point to LH side of car using 4 off M8 x 25 s...

Page 503: ... Silver dependent on body colour see above Lotus Sport is moulded into one of the spokes of each wheel Cup and Exige S models use standard Exige wheels finished in hi power silver The Lotus specific regular Exige Yokohama A048 tyres identified by LTS are fitted as standard EXIGE S C J BRAKES For 240R and Cup models the braking system is uprated in the following respects Motorsport brake pads are fitted...

Page 504: ...C Q CLUTCH 240R and Cup cars use an uprated clutch cover assembly and a competition specification sintered metal fric tion plate No routine maintenance is required other than annual renewal of the Castrol SRF hydraulic fluid EXIGE S C Z MISCELLANEOUS Supercharged models also differ from standard Exige in the following respects Engine dipstick tube altered to avoid supercharger Relays on engine bulkh...

Page 505: ...Chassis 2 Eleven A 5 Body 2 Eleven B 5 Front Suspension 2 Eleven C 9 Rear Suspension 2 Eleven D 9 Engine 2 Eleven E 11 Wheels Tyres 2 Eleven G 17 Brakes 2 Eleven J 17 Cooling 2 Eleven K 18 Fuel System 2 Eleven L 19 Electrical 2 Eleven M 20 Maintenance Lubrication 2 Eleven O 26 Miscellaneous 2 Eleven Z 26 Circuit Diagrams Index 27 ...

Page 506: ...hares that car s basic chassis and supercharged powertrain componentry but uses a new chargecooler arrangement and peripheral systems Unique engine programming is used in conjunction with 4 high flow fuel injectors as used on Exige Cup cars The open top lightweight body is designed to be amenable to economic accident repair and is supplemented by an FIA compliant roll over bar and strut mounted rea...

Page 507: ...ght SVA 745 kg incl full fuel tank Maximum weight 895 kg incl occupants Capacities Engine oil refill incl filter Accusump 6 4 litre The oil cooler circuit contains an additional 3 5 litres but this volume is not normally drained during routine servicing Engine Forced induction Magnuson MP62 supercharger with integral by pass valve Air air chargecooler Maximum boost pressure 0 5 bar 7 psi Max power 2...

Page 508: ...h adjustable spring top platforms Suspension Geometry at mid laden ride height Front Castor 3 5 to 4 5 3 30 to 4 30 max side side 0 4 0 24 Camber 1 5 to 1 3 1 30 to 1 18 max side side 0 4 0 24 Alignment 0 4 mm to zero Steering axis inclination 11 54 to 12 06 Rear Camber 2 75 to 2 48 2 45 to 2 29 Alignment 1 2 to 1 5 mm toe in each side Electrical Battery type Odyssey PC680 rating PHCA 5 second 680...

Page 509: ...rails with the front bracing struts locating against the joint between the side rail top and scuttle cross beam and secured by similar riveted tapping plates The rear bracing struts use a single fixing bolt at each side to secure to the rear subframe The roll over bar complies with FIA requirements for international motorsport but note that any additions or modifications to the bar may invalidate su...

Page 510: ...anel in the rear body is secured by two recessed Aerocatches and provides access to the engine for maintenance operations To remove the cover at each latch press the smaller section of the flush fitting latch plate to allow the latch plate lever to spring up Fully raise the lever to release the latch Lift the rear of the panel and then draw rearwards to disengage the front flange from beneath the rea...

Page 511: ...nting and duct for the oil cooler as well as tying the front corner of the body to the splitter panel The quarter panel is fixed by 2 screws from beneath through the splitter into captive nuts in the quarter panel lower flange 2 screws down through the front body flange into captive nuts in the quarter panel upper flange Front Wheelarch Shields A small moulded plastic panel is fitted within each front ...

Page 512: ...Each type should only be used with the corre sponding front splitter panel in order to maintain the correct aerodynamic balance Both aerofoil types are mounted via machined alloy support plates to the top surface of the rear subframe Each plate uses an angle bracket at its base to secure to the subframe and two of the same angle bracket to brace the plate to the rear clamshell through which the pl...

Page 513: ...ck use 11 clicks from full hard Rebound damping is adjusted via a ribbed collar below the bottom spring seat Turn clockwise as viewed from below to increase damping and counterclockwise to decrease Recommended settings are as follows Road use 8 clicks from full hard Track use 8 clicks from full hard The motorsport stiffened and 5 position adjustable front anti roll bar included as part of the Spor...

Page 514: ...bbed collar below the bottom spring seat Turn clockwise as viewed from below to increase damping and counterclockwise to decrease Recommended settings are as follows Road use 15 clicks from full hard Track use 12 clicks from full hard All cars are equipped with through bolted spherical joints on the inboard ends of the rear toe links allied to a tubular steel crossbrace connecting the rear sides o...

Page 515: ...nk of the chargecooler Each end of the chargecooler is mounted by two alloy spacers to a fabricated steel mounting bracket se cured to the engine crankcase by a single fixing bolt A bonded rubber bush at this position supresses vibration effects and in conjunction with the rubber hose connections to the inlet and outlet ducts provides an isolated mounting of the chargecooler A re shaped breather pi...

Page 516: ...harger adaptor fixings Chargecooler Fixing point s c inlet outlet duct to manifold By pass valve Fixed to engine capsule mounting plinth Front Support strut to clutch slave cylinder mounting Alternator anchor e235 Cooling air intake duct Chargecooler Collector Outlet to engine Charge air temperature sensor Cooling air Alloy trunking to Inlet spacer chargecooler from s c Rear Fixing bracket to to cr...

Page 517: ... dipstick will depend on the amount of oil stored in the Accu sump which itself is dependent on the both the Accusump pre charge air pressure and the engine oil pressure when the ignition was switched off Before checking the oil level the Accusump pre charge pressure should first be checked turn on the ignition to open the EPC valve and allow the stored oil to be discharged from the Accusump The pr...

Page 518: ... the alternator Release the dipstick tube from the supercharger 4 Using a strap wrench remove the supercharger pulley retaining nut and slide off the pulley 5 Remove the support strut between the throttle body adaptor and the clutch slave cylinder Slacken the pinch bolt securing the supercharger to the nose bracket Remove the two bolts supporting the super charger to the inlet manifold and withdra...

Page 519: ...x 25 with A130 Tighten the three support strut bolts to 25 Nm Carefully tighten the two M10 x 50 flange head bolts to pull in the two spacers evenly to clamp against the supercharger 6 Refit the alternator upper bolt and spacer and tighten to 25 Nm Tighten the lower bolt to 25 Nm 7 Fit the pulley to the supercharger with the longer boss towards the charger Fit the nut onto the shaft and use a strap ...

Page 520: ...scard the old synthetic drive cou pling and fit the new part supplied in the oil fill kit onto the three pegs on the rotor drive gear Check that the two alignment dowels are fitted in the supercharger body flange 5 Fill the gear case with 120 ml of Magnuson Products Supercharger oil as supplied in the oil fill kit 6 Clean the mating face on the supercharger body and on the new nose housing and apply a ...

Page 521: ...ch plates between each differential output gear and the differential carrier The load applied to the clutch pack is proportional to the input torque via a cam and ramp angle design incorportated between the 4 pinion spider driven by the crownwheel and the two clutch pack assemblies The stiffness of the LSD operation is dependent on the ramp angle which may be specified on ordering A 2 way LSD uses ...

Page 522: ...the material Bedding Procedure To generate some heat in the discs and pads perform 4 to 6 stops with medium brake pressure from around 70 mph 110 km h to 40 mph 60 km h allowing around 30 seconds between stops The pad temperature should not exceed 400 degrees C Immediately after this procedure carry out one high speed stop with medium to heavy brake pressure without activating the ABS from around ...

Page 523: ...ngine bay Two grilled air intakes at the rear of the cockpit sides supply a plenum on the front of the chargecooler radiator Hot air exhausts from the engine bay via an aperture in the rear body 2 ELEVEN L FUEL SYSTEM In order to meet the fuelling requirements of the 255 PS engine specification a high output fuel pump is fitted in the otherwise unchanged tank This pump is slightly longer than the st...

Page 524: ...ch but ton lights up green to indicate when the circuit is active The steering column lever switch see later is used to select main or dip beam Pressing the switch a second time will switch off the headlamps but leave on the sidelamps see above Hazard Warning Lamps Switch The hazard warning switch is located at the left hand end of the panel and has an icon in the switch but ton which is back lit ...

Page 525: ...s feature which operates at all speeds above 6 mph can improve vehicle stability in some extreme conditions of use especially where variable surface grip prevails or when maximum vehicle performance is being exploited The optional Torsen type Limited Slip Differential LSD is a mechanical gear system incorporated into the final drive unit and limits the speed differential between the two rear wheels...

Page 526: ...vel of traction control see above noting that the launch control setting will not be affected Engage first gear apply full throttle ECU limits engine speed to selected launch rpm and rapidly drop clutch Maintain full throttle throughout the transition from launch to traction control at around 6 mph until the first gear change is required To disable launch control when variable traction control is st...

Page 527: ...insert the key press down and turn a quarter clockwise The key is now captive Battery Charging The Odyssey PC680 battery fitted to the 2 Eleven uses aborbed glass mat AGM technology to provide the virtues of both deep cycling ability and high cranking power Thus low rate long duration drains and short duration high amperage pulses are accommodated The battery is fully sealed recycling all gases int...

Page 528: ...olonged period may not be recoverable to its original condition Allow several hours after disconnecting a charger before measuring the battery voltage WARNING Hydrogen gas generated by the battery could cause an explosion resulting in severe personal injuries Charge battery in a well ventilated area Never charge a frozen battery It may explode because of gas trapped in the ice Allow a frozen batte...

Page 529: ...et 4A Pink 5A Orange 7 5A Brown 10A Red 15A Light Blue 20A Yellow 25A Clear Slot Rate Circuit E1 7 5A Engine control relay E2 15A Cooling fan 1 E3 15A Cooling fan 2 E4 Not used Slot Rate Circuit F1 15A Batt services F2 15A Ign services F3 20A Fuel pump F4 10A Main relay Slot Rate Circuit R1 5A Turn lamps R2 5A Rain lamp Slot Rate Circuit R3 5A Rvrs lamps R4 5A Stop lamps Slot Rate Circuit A1 Not u...

Page 530: ...ter 12 being F or G and only whilst being used in the U K It is permissible for the car to be driven on closed circuits or private test tracks but using the car in a competitive manner including timed runs or laps will invalidate the Lotus Vehicle Warranty Warranty Periods Warranty period for vehicle 12 months 12 000 miles Warranty period for replacement parts 12 months 12 000 miles Corrosion perf...

Page 531: ...1 Turn Indicators Side Hazard Warning Lamps Sheet 5 Page 32 Switch Pack Headlamps Sheet 6 Page 33 Instruments Sheet 7 Page 34 Engine Cooling Fan Sheet 8 Page 35 Horn Rain Lamp Relay track option Sheet 9 Page 36 ABS Traction Control Sheet 10 Page 37 Harness Ground Splices Sheet 11 Page 38 Fuse Layout base SVA cars Sheet 12 Page 39 Power Ground Structure Sheet 13 Page 40 Fuse Layout base track cars ...

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