Lotus 2004 ELISE Service Notes Download

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Summary of Contents for 2004 ELISE

Page 1: ...SERVICE NOTES LOTUS CARS LTD Norwich Norfolk NR14 8EZ England Telephone 0 1953 608000 Telefax 01953 608300 Part Number A111T0327J Lotus Cars Ltd 1996 ...

Page 2: ...ury to persons or damage to property Lotus policy is one of continuous product improvement and the right is reserved to alter specifications at any time without notice Whilst every care has been taken to ensure correctness of information it is impossible to guarantee complete freedom from errors or omissions or to accept liability arising from such errors or omissions but nothing herein contained ...

Page 3: ...Engine inc Rover publication RCL 0057ENG EE Engine Management EMN Transmission inc Rover publication RCL 0124ENG FH Wheels Tyres GF Steering HE Brakes JH Engine Cooling KF Fuel System LH Electrics MN Maintenance Lubrication OG Heating Ventilation PF Air Conditioning Heating Ventilation 2000 M Y PH Clutch QF Motorsport XA 340R Supplement 340R Exige Supplement Exige 2000 04 Page 1 ...

Page 4: ...actory records are filed against V I N and specification change points are identified by V I N or engine number The vehicle licence number may not accurately reflect vehicle age may also be changed during the car s life and is an unreliable method of vehicle identification The V I N comprises 17 characters coded in accordance with European Economic Community EEC directives Note that the coding of ...

Page 5: ...RTRAY DIFFUSER For certain service operations it may by necessary to remove the engine bay undertray and or diffuser panel The panels are retained by Four M8 button head fixings needing a 5mm hexagonal key Fourteen M5 crosshead screws 2000 OS Page 3 ...

Page 6: ... time for wheel changing lifts both wheels on one side Do not use with a four point garage lift B Beneath the front end of the right or left hand main chassis rail behind the front wheelarch Garage use with 4 point lift in conjunction with C C The engine undertray diffuser panel must first be removed Beneath the outboard end of the chassis crossmember ahead of the rear wheelarches Take care to pos...

Page 7: ...l fuses in front luggage compartment Optional U K Market Cobra 6422 Alarm October 97 VIN W 1947 onwards Plus 1937 1938 Option upgraded from Cobra 6019HF to 6422 Facility to reprogramme transmitter keys Override switch deleted Front Brake Disc Shields December 97 VIN W 2260 approx Alloy shield fitted on inboard side of front discs to protect from debris and balance pad life Revised Soft Top Cant Ra...

Page 8: ...iator air intake radiator outlet engine lid outlet rear clamshell recess engine bay intake All cars have gold painted 111S type road wheels black and gold Alcantara steering wheel gold painted dash insert panels 111S type black leather seats with gold Alcantara centres gold decals on rear body and dash black gold nose badge Union Flag decal on rear Standard versions also have headlamp covers and r...

Page 9: ...eels plinth mounted rear aerofoil Alcantara trimmed seats and steering wheel pad body decals Exige July 00 VIN Y 0001 Character 13 8 model specific serial number sequence Road going version of the Elise race series car with 178 bhp 340R engine close ratio transmission sport suspension and larger 12 spoke black finish wheels 16x7 17x8 5 with Yokohama A039 tyres Front and rear clamshells styled as r...

Page 10: ...Page 8 2000 03 ...

Page 11: ...TA ENGINE SECTION TDL M111 ELISE Page General 2 Cylinder Head 2 Camshafts Valve Timing 2 Valves 2 Valve Guides 3 Valve Seats 3 Valve Springs 3 Crankshaft 3 Piston Rings 3 Piston 3 Cylinder Block 3 Oil Pump 4 Coolant Thermostat 4 M M f l 2 Page 1 ...

Page 12: ...ith MEMS 2J engine management Unleaded 95 RON minimum 88 kW 118 bhp 5 500 rpm 107 kW 143 bhp 7 000 rpm 165 Nm 122 Ibf ft 3 000 rpm 174 Nm 128 Ibf ft 4 500 rpm CYLINDER HEAD Material Aluminium alloy Head face maximum warpage 0 05 mm Cylinder head height new 118 95 to 119 05 mm reface limit 0 20 mm Std Open duration Inlet valve opens Inlet valve closes Exhaust valve opens Exhaust valve closes Valve ...

Page 13: ...limit Thrust washer thickness Main journal diameter Maximum out of round Big end journal diameter Maximum out of round Big end clearance 0 10 0 25 mm 0 34 mm 2 61 2 65 mm 47 979 48 007 mm for grading see Section EE 0 010 mm 47 986 48 007 mm for grading see Section EE 0 010 mm 0 021 0 049 mm PISTON RINGS New ring to groove clearance top compression 0 040 0 072 mm second compression 0 030 0 062 mm o...

Page 14: ... OIL PUMP Outer rotor to housing clearance Inner rotor tip clearance Rotor end float COOLANT THERMOSTAT Nominal setting Thermostat starts opening Thermostat fully open 0 28 0 36 mm 0 05 0 13 mm 0 02 0 06 mm 85 91 C 88 C 100 C Page 10 ...

Page 15: ...TECHNICAL PATA VEHICLE SECTION TDM M111 ELISE Page Dimensions 2 Capacities 2 Tyres 2 Winter Tyres 3 Wheels 3 Front Suspension 3 Rear Suspension 4 Electrical 4 Transmission 4 Clutch 5 Brakes 5 Steering 5 Fuel Consumption 5 2 0 0 0 6 2 ...

Page 16: ...1664 lb front 303 kg 668 lb rear 452 kg 996 lb inc full fuel 111S total 770 kg 1698 lb front 303 kg 668 lb rear 467 kg 1030 lb Max weight std total 974 kg 2147 lb front 386 kg 851 lb rear 588 kg 1296 lb inc 111S total 992 kg 2187 lb occupants front 376 kg 829 lb luggage rear 616 kg 1358 lb Trailer towing Not permissible 5 0 litre 8 8 imp pt 4 5 litre 7 9 imp pt 1 0 litre 1 8 imp pt 2 4 litre 4 2 i...

Page 17: ...6 bar 23 lb in2 rear 1 7 bar 24 5 lb in2 WINTER TYRES Type Size front rear Pressure cold front rear Studding Tyre chains WHEELS Type std prior April 99 approx VIN X 6429 std from April 99 approx VIN X 6429 111S std option Size front rear std 111S std option PCD Inset front rear std 111S std option Wheel nut torque Michelin XM S 130 185 55 R15 81T 195 60 R15 88T mounted on standard 15 inch front wh...

Page 18: ...1 SCC BA15s Stop tail lamps 5 21 SBC BAY15d High mounted stop lamp 11 891 Rear fog lamp 21 SCC BA15S Reversing lamp 21 SCC BA15s Licence plate lamps 5 SU 8 5 8 Interior lamp 10 SU 8 5 8 Fascia switches 1 2 W2x4 6d System voltage polarity Alternator Battery type cranking power reserve capacity European Type Number ETN 12V negative earth 85A Tungstone 063 380 A SAE 21 OA DIN 38Ahr 60 minutes 543 16 ...

Page 19: ...phragm spring cover Hydraulic release 215 mm 1 00 mm 37 5 32 1 mm 42 75 mm 7 4 6 9 mm 5 6 mm 1 00 mm 0 20 mm 0 80 mm 1 00 mm 0 15 mm Ventilated front rear discs Opposed piston alloy front calipers Single piston sliding rear calipers Aluminium metal matrix Cast iron 282 5 mm Tandem master cylinder Cable operation of rear calipers self adjusting for pad wear Rack and pinion 2 4 15 8 1 FUEL CONSUMPTI...

Page 20: ...Lotus Service Notes Section AF CHASSIS SECTION AF M111 Sub Section Page General Description Chassis Straightness Check Rear Subframe Longerons AF 1 3 AF 2 4 AF 3 5 2000 02 Page 1 ...

Page 21: ...Composite crash structure Scuttle beam Door hinge mounting Sill extrustion E L I S E C H A S S I S U N I T Seat mounting extrusion Steel rool hoop Main siderail Rear longeron Steel rear subframe Fuel tank bay fa29l ...

Page 22: ...eet steel fabricated subframe which provides mountings for the rear suspension pivots engine rear stabiliser and exhaust muffler Onto each top side of the subframe is bonded and rivetted a box section extrunded alloy longeron which extends rearwards to provide rear body support Enhanced stiffness of the chassis rear section and additional occupant protection is provided by a tubular steel roll ove...

Page 23: ... of each chassis main side rail At the front end between the suspension wishbone pivots and at the extreme rear end of each rail 2 Measure the height of each tooling hole above the reference plane and use jacks to adjust the height of the chassis in order to equalise any three of these dimensions 3 Measure the deviation of the fourth dimension from the other three Maximum service deviation 2 0 mm ...

Page 24: ...re used the longeron must be cut from the subframe Fitting rear subframe When bolting the subframe at each side to the chassis rail rear flange ensure that the anti corrosion shim plate is interposed The lower fixing bolts should be inserted from the rear and the upper bolts from the front Torque tighten the bolts to 45 Nm If longerons are already fitted to the subframe fit the rear damper mount t...

Page 25: ...o position between the longerons before inserting the three 6 4 mm 1 4 rivets each side to secure the longeron and boot floor if applicable to the subframe Fit the M10 caphead screw and washer to secure the roll over bar stay and longeron to the damper mounting tapping block 6 Fit the exhaust heatshield electrical component plate and other components in reverse order to removal Tapping block Longe...

Page 26: ...Features BM 2 3 Bodycare BM 3 3 Accident Damage Assessment BM 4 5 Body Panel Bonding Materials BM 5 6 Replacement of Bonded On Panels General BM 6 9 Front Crash Structure BM 7 10 Windscreen Frame BM 8 12 Sill Panels BM 9 16 Rear Bulkhead Panel Capping Rail BM 10 18 Page 10 Lotus Service Notes Section TDL ...

Page 27: ...Service Notes Section TDL Principal Body Components Windscreen frame scuttle RH door shell Front compartment lid Engine cover lid aluminium alloy Crash structure Chassis structure aluminium alloy iizzl Page 2 ...

Page 28: ...lises a single moulding for the whole of the nose and front wings and a second one piece moulding for the whole of the rear body aft of the doors These two mouldings are fixed using threaded fasteners to permit easy removal for access to chassis or powertrain components or to allow simple and economic accident repair Other composite mouldings include the door shells sills front compartment lid win...

Page 29: ...bodywork 6 Remove surface water with a sponge and allow to air dry in direct sunlight Ensure that the roof is fully dry before stowing as prolonged stowage of a wet or damp roof will promote rotting of the fabric Keeping the soft top clean by regular washing will enhance the life and maintain the appearance of the roof and facilitate subsequent cleaning The use of stronger cleansers should be left...

Page 30: ...nt Lid Note that the engine cover lid is aluminium These panels are secured by threaded fasteners and are easily removed for access to the back of any damaged area for repair by conventional composite techniques Instructions for the removal and refitment of the front and rear clamshells and doors are contained in section BN Bonded or Panels Windscreen Frame LH RH Sill Panels Front Crash Structure ...

Page 31: ... Lotus part no A100B6008V Betaprime VP 01706 A B Lotus part no A100B6070V Betaseal 1701 Lotus part no A082B6281F Glass Cleaner Betawipe VP 04604 Primer Betaprime 5001 Adhesive Betaseal 1701 or Betamate E2400 Lotus part no A082B6150V Lotus part no A100B6009V Lotus part no A082B6281F Lotus part no A082B8415V Uncoated Lexan Perspex Cleaner Abrasion dry wipe Primer Betaprime 5404 Adhesive Betaseal 170...

Page 32: ...h Do not wipe off Allow 2 3 minutes flash off time before applying adhesive 5001 A100B6009V Adhesion promotor used to maximise the performance of the bonding between the cleaned and or activated surface and the adhesive compound Supplied in 250 ml aluminium con tainer with GREEN coloured cap Two steel balls inside the container are provided to assist mixing of the contents when shaken Prior to dec...

Page 33: ...r bottle and wet out the felt pan by inverting the bottle and gently squeezing the sides Wipe the pad over the cleaned substrate surface to apply a continuous THIN film of primer A thin almost transparent film is all that is required No attempt should be made to attain a completely opaque covering Allow to dry for a minimum of 4 HOURS before applying adhesive To achieve a continuous thin film of V...

Page 34: ...nel to be removed The recommended method of adhesive cutting is with the use of a pneumatic tool such as the Chicago Pneumatic CP838 Pneu Nife which uses a range of differently shaped cutting knives to which is imparted a vibrating action This tool may also be used to remove windscreens Supplier Chicago Pneumatic Utica New York 13501 USA Catalogue no CP838 Pneu Nife Recommended air pressure 60 90 ...

Page 35: ...ong and durable bonds are to be obtained Always use the specified materials BM 7 FRONT CRASH STRUCTURE The front crash structure consists of an upper and lower moulding bonded together and supplied only as an assembly It is bonded to the front face of the chassis and is braced by a flat alloy undershield screwed to the bottom front edge of the chassis and to each lower side of the crash structure ...

Page 36: ...e rendering the unit unsuitable for refitment Take care not to damage the surface of the chassis when cutting the adhesive It is not necessary to remove all traces of old adhesive from the chassis but a uniform surface must be available for the new adhesive bead The remaining adhesive must be securely bonded and be cut with a scalpal blade to leave an even thickness of 1 2 mm Prepare the new struc...

Page 37: ...ield radiator see sub section KF 4 front clamshell see sub section BN 4 and remaining parts BM 8 WINDSCREEN FRAME The windscreen frame is a single VARI moulding incorporating hollow foam filled sections and includes the fascia top and a forward extending buttress at each side to brace the frame to the front chassis A sepa rately moulded demist duct is bonded to the underside of the fascia top and ...

Page 38: ...innacle and dash panel see sub section BN 12 5 Release the brake hose pipe connector at the front end of each buttress on the windscreen frame 6 Disconnect the wiper motor harness and windscreen washer tubing Release all relays fuses and har nesses from the buttresses as necessary 7 Use a sealant cutting tool to cut the bond between the buttresses and chassis buttresses and sill panels and between...

Page 39: ... sufficient spread of adhesive Retain to the chassis with two rivets and clamp as necessary until the adhesive cures 11 Prepare the old adhesive bead on the chassis for fitment of the windscreen frame by removing excess sealant from all the bonding areas on the chassis sill panels and dash baffle to leave a consistent and level bonding surface for the new frame It is not necessary to remove all tr...

Page 40: ...ls into position and secure the frame such that the cant rails are held against their striker plates on the roll over bar but with out the foam seals on their front end being compressed After further assembly the thickness of the header rail moulded carrier strip and tongue strip see sub section BN 14 provide the appropriate seal compression to locate the cant rails Windscreen frame bonding sills ...

Page 41: ...ront and rear clamshells see sub sections BN 4 BN 5 and dash panel BN 12 Remove the clamshell mounting bracket at the bottom corner of the windscreen 2 Remove the cant rail striker from the top of the sill B post to the roll over bar and the door latch striker pin 3 Remove the speaker panel from the cabin rear corner and remove the engine lid release cable from the sill panel 4 Use a sealant cutti...

Page 42: ...e adhesive see sub section BM 5 to the bonding surface on the chassis and body and fit the sill panel into position first locating the sill bottom edge into its chassis slot and press all around the joint to ensure sufficient spread of adhesive If necessary use a spatula to smooth or remove any extruded adhesive and to neaten any visual areas If necessary add adhesive to the gaps around the door h...

Page 43: ...in accordance with sub section BM 5 3 Locate the capping rail around the roll over bar stays before applying a bead of Betaseal mate to the top and bottom joint flanges of the bulkhead and also to the sill flange if one sill is already fitted Fit the bulkhead into position with the vertical flange on the bottom of the panel against the rear face of the chassis fuel tank bay Fit the capping rail to...

Page 44: ...ll BN 4 7 Rear Clamshell BN 5 8 Door Mirrors BN 6 10 Door Beam Hinge BN 7 12 Door Shell Assembly BN 8 13 Door Glass Guide Channels Winder Mechanism BN 9 14 Door Seals BN 10 17 Door Latch Mechanism BN 11 20 Instrument Binnacle Dash Panel BN 12 22 Windscreen BN 13 25 Roof Header Retaining Strip BN 14 28 Decal Positioning BN 15 29 Rear Boot Bulkhead BN 16 30 Page 10 ...

Page 45: ...ss Place the fairing onto the roll over bar and press the glass top edge against the flange on the fairing to compress the seal and allow the window to be retained by the two tangs Hook the single over centre latch at To remove the window and fairing press down the safety catch before disengaging each over centre latch and lifting off the fairing Lift out the rear window from its channel and store...

Page 46: ...n is fully engaged before using the hexagonal key provided stowed in the corner panel behind the left hand seat to turn each cam pin to tension the roof Right hand pin clockwise Left hand pin counterclockwise Tensioning roof Roof bows erected lohs6 7 5 Push the two roof bows rearwards to their upright position to fully tension the roof Soft Top Roof Removal Stowage 1 Push both roof bows forwards t...

Page 47: ...dry it should be stowed for no longer than a few days before unrolling or refitting and allowing to air dry completely Prolonged stowage of a wet or damp roof will promote rotting of the fabric The roof may be treated periodically with Fabsil silicone waterproofer A111B6061 especially on the cant rail flaps and seams in accordance with the manufacturer s directions BN 2 FRONT BONNET The front bonn...

Page 48: ... of the panel If removing the bonnet take note of the shim stack for re assembly and when the bonnet is removed guard against damage being caused to the radiator matrix by the hinge elbow if the hinge blade should be inadvertently pressed downwards Bonnet panel plinth Pivot screw Thrust washers Shim plates Hinge blade Pivot bush Clamshell gutter Hinge bracket CEEfl Bonnet Hinge A hinge bracket is ...

Page 49: ... of the panel is controlled by the setting of the striker pin which may be screwed up or down as required The height of the front edge is controlled by the number of shim plates fitted between the hinge blade and the panel with slotted holes in the blade allowing for positional adjustment of the panel Pivot screw Engine lid plinth plates Hinge blade Thrust washers Clamshell fixing Pivot bush Hinge...

Page 50: ...iners 3 Remove the two M8 fixings securing the lower rear edge of the clamshell to the top of the sill 4 Remove the single M8 screw securing each top rear corner of the clamshell to a bracket at the top of the A post 5 Remove the four fixings in the bonnet gutter one at each rear end and one in each front corner The rear pair are also used as adjustable mounts for the bonnet closing buffers and us...

Page 51: ...e of the moulding in order to stiffen the panel and provide a mounting point to the chassis The clamshell is secured to the chassis and other body panels by threaded fasteners for ease of service access and body repair To Remove Rear Clamshell 1 If fitted remove the roll bar fairing and rear window 2 Remove both rear roadwheels 3 Remove the fixings securing both rear wheelarch liners Two fixings a...

Page 52: ... harness connectors to the rear fog and reverse lamps 9 Remove the rear number plate and release the single fixing securing the clamshell to the rear tray bracket 10 Remove the fuel filler cap and release the four screws securing the fuel filler neck to the clamshell Remove the washer ring and withdraw the neck from the clamshell aperture 11 From inside the cockpit remove each rear comer speaker t...

Page 53: ...ually adjustable plastic housed door mirrors are mounted via an injection moulded plinth to the door shell A spring loaded ball and socket arrangement provides a means of mirror adjustment and a sprung attachment of the mirror housing to the pivot socket allows for the mirror to move forwards or backwards on accidental contact in order to reduce the poten tial for personal injury or vehicle damage...

Page 54: ...screwdriver or similar tool to remove the screw recessed into the inside face of the mirror plinth Fixing screw Mirror assembly Mirror mounting plinth fb24l1 Replacement of mirror plinth The mirror plinth incorporates tapping plates to accommodate a single screw into the top leg and a pair of M5 screws into the bot tom leg Access to the recessed socket head upper screw is readily available but acc...

Page 55: ...chassis outrigger and allow for some vertical movement Horizontally slotted fixing holes in the hinge bracket allow for fore aft movement Slotted shim plates fitted between the hinge bracket and chassis allow the in out door front edge align ment to be adjusted in steps of 1mm and by varying the shim pack at the top and bottom pairs of fixings the vertical alignment as viewed from the front may be...

Page 56: ...l after the inner and outer door mouldings have been bonded together during manufacture If a door is to be removed from the car the preferred method is to release the M10 cap head screws clamping the upper and lower bushes to the door beam The beam and door shell assembly may then be withdrawn from the hinge stator bracket without losing adjustment of the hinge alignment and door shutlines If the ...

Page 57: ...o secures the rear guide rail after the glass has been fitted and the position of the rear guide rail adjusted BN 9 DOOR GLASS GUIDE CHANNELS WINDER MECHANISM A manually operated door window scissor type lift mechanism is used in conjunction with two aluminium guide channels and a frameless door design The operating principle of the window lift mechanism is that of a scissor linkage with the front...

Page 58: ...mechanism Reaction channel Re shim if necessary m i H o m d Move sideways to adjust lean Move reaction channel to adjust front rear height Move fore aft to adjust pinch Top fixing behind felt insert Primary scissor arm pivot Move sideways to adjust lean b285 1938 0 1 Page 15 ...

Page 59: ...he position shown and fit a mesh friction washer between the eccentric and the sector Mesh washer A111U0251F 11mm Drill 6mm clearance hole Existing hole Eccentric stop B111U0084F b274 2 Establish whether the car is fitted with window upstop L brackets introduced in November 96 at VIN V 244 Note that it is not practicable to update earlier cars due to the requirement for captive fixings within the ...

Page 60: ...ge should make light contact with the soft top material If necessary slacken the eccentric adjuster on the toothed sector and the reaction channel to the door shell Then if no upstop t brackets are fitted on the door beam Overall glass height is controlled by the eccentric stop and fore aft alignment height by the position of the reaction channel To raise the front edge of the glass lowerthe react...

Page 61: ...Lotus Service Notes Section BN Blank page Page 16b 1998 01 ...

Page 62: ...nnel and leave to cure overnight before re assembling Note that some penetrant lubricants e g WD40 have a detrimental effect on the bonding medium and should be used only with discretion To replace door winder mechanism 1 Remove the door trim panel Unclip the cap from the window winder handle release the retaining screw and withdraw the handle Release the seven fixing screws and remove the door tr...

Page 63: ...lass edge and the seals Door glass guide channels The front guide channel is secured by two screws through the bottom face of the door shell into captive spring steel nuts on the channel bottom flanges and by a single countersunk screw at the top end into a captive M5 nut in the mirror mount area This top screw is covered by the guide channel insert silent channel Note that the front guide channel...

Page 64: ...nels but may require some lubrication with a sili cone spray before fitting but take care not to contaminate the stud carrier adhesive on the bottom of the door glass Rear channel top fixing Rear guide channel Guide channel lower fixing BN 10 DOOR SEALS Drop Glass Inner Waist Seal The hollow section inner seal is flocked on its glass contact surface and is pressed onto a horizontal metal flange bo...

Page 65: ...f the latch striker pin and a small D section weir is stuck to the front shut face of the door to provide optimum sealing of this area Before fitting a new weatherstrip ensure first that the foam rubber tapered packing strip is fitted to the top part of the windscreen pillar degrease the appropriate area on the pillar and apply PP Primer 3842 A082U6199V to both the pillar and packing strip Lay dou...

Page 66: ...eal until centralised about the latch striker pin Remove the wire and seal the hole in the weatherstrip Door seal buffer Cut off loop after positioning Top end of door weatherstrip Buffer centralised about striker pin Stiff wire pull through Door Weir A 377 mm length of small D section hollow rubber weir is stuck to the front shut face of the door 15 mm from the outer edge of this surface Double s...

Page 67: ... the latch mechanism via two short links and a relay lever The interior release handle is mounted forward in the door inner shell and is connected to the latch mechanism by a control rod No interior control of door locking is provided Interior release Relay lever Exterior release rod To replace interior release handle Remove the release handle trim panel by releasing the two screws in the panel fr...

Page 68: ...crew and withdraw the handle Release the seven fixing screws and remove the door trim panel Unclip the control rod from the interior release handle and unhook from the latch mechanism Unclip and dis connect the short link between the relay lever and the latch mechanism Remove the three M6 screws securing the latch mechanism to the door and withdraw the latch Control rod to latch Outboard Rod to ex...

Page 69: ... from the channel Do not attempt to withdraw the glass from the door without first removing the door glass inner waist seal or damage to one or both waist seals will result 5 Remove the access grommet from the rear face of the door and unclip the exterior lock link rod from the relay lever Similarly disconnect the link rod between the relay lever and the latch mechanism 6 Support the door shell be...

Page 70: ...t as is the fascia top and inside surfaces of the windscreen surround To Replace Instrument Pack For access to the instrument pack mounting brackets it is necessary first to re move the column shroud Release the four screws securing the shroud upper section turning the steering wheel as necessary to permit access Pull out the grommet from around the ignition switch and remove the three screws secu...

Page 71: ... used along the top edge of the dash top extrusion to inhibit rattles 5 Release the heater controls and audio set if fitted from the dash centre panel and remove the four screws securing the panel to the dash lower panel two screws outboard of column If necessary de press the retaining tabs on the push switches to remove the switches from the outboard centre panel 6 Before removing the lower panel...

Page 72: ...pindle and the interior mirror from its plinth 2 In order to allow access to the lower edge of the screen the rear of the front clamshell must be released At each side release the rear end of the wheelarch liner and remove the screw securing the clamshell to the front end of the sill At each side release the screw securing the bottom rear corner of the clamshell to the sill At each side release th...

Page 73: ...ermost and hold in place for 2 to 3 minutes Allow at least 10 minutes curing time before fitting the mirror Windscreen top edge Obscuration band Mirror position on RHD offset to left Screen centreline 79 mm 63 mm 63 mm Mirror position on LHD offset to right 7 Clean the whole of the inside surface of the obscuration band and the laminated edge of the glass with the wipe cleaner Similarly clean the ...

Page 74: ... 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 to fully cure and cut away any excess using a scalpel blade 13 Use duct tape and or support blocks to hold the screen in position and do not disturb until the Betaseai is fully cured This will take approximately 4 hours dependent on a...

Page 75: ...RETAINING STRIP To retain the front of the soft top roof an aluminium tongue strip is fixed to the top of the windscreen header rail via a moulded plastic carrier A textured gripper strip is applied to the top of the tongue to help stabilise the soft top and to cover the tongue fixings and a small D section seal is glued to the header rail ahead of the tongue carrier The following procedure descri...

Page 76: ...erstrip to the carrier using Loctite 480 adhesive 4 Release the screws securing both tongue strips and carriers and clean the mating surfaces of the tongue carriers and header rail with Betaclean Apply a thin bead of black Silastic to the underside of the carriers and fit the carriers and tongue plates drilling the remaining pilot holes and retaining with the screws Seal the top end of the door we...

Page 77: ... to provide a mounting for the optional rear boot bag and lid an alloy bulkhead is fitted between the engine and the rear luggage compartment A bulkhead may be fitted to a car built without one without removing the rear clamshell as follows Boot Lid Clamshell gutter Boot bulkhead Rear longeron Boot bag V clip Foam strip Boot bag Luggage compartment floor b271 Page 30 ...

Page 78: ...ding area on the sidewall and secure the bulkhead into position with three screws along the bottom edge into thread inserts in the floor front edge and two screws each side into the rear longerons Fit a single screw through the rear lid gutter into each top end of the bulkhead 3 Fit the boot lid to the top surface of the bulkhead using 9 fasteners 4 Fit the boot bag by securing with 5 turnbuckle f...

Page 79: ...ction CG FRONT SUSPENSION SECTION CG M111 ELISE Sub Section Page General Description CG 1 3 Geometry Adjustments CG 2 3 Anti Roll Bar CG 3 6 Suspension Disassembly Assembly CG 4 8 Front Wheel Bearings CG 5 10 1998 02 Page 1 ...

Page 80: ...ERAL LAYOUT Spring damper unit Top wishbone Late type anti roll bar mounting Anti roll bar Bottom wishbone Hub carrier Steering tie rod Upper swivel Track rod end Steering arm Wheel hub Lower steering swivel joint Ic34 I Page 2 1998 02 ...

Page 81: ...front crossmember and is fitted with the damper rod lowermost in order to minimise unsprung weight In order to protect the alloy hub carrier from the effects of electrolytic corrosion it is important to ensure that the joint faces with any steel components are coated with the specified jointing compound before assem bly CG 2 GEOMETRY ADJUSTMENTS Provision is made for the adjustment of wheel alignm...

Page 82: ...opposite side Turn each track rod a similar amount As a guide turning both track rods by one quarter of a turn will alter overall toe out by approx 2 0 mm When adjustment is correct hold each track rod end and tighten the locknuts to 80 82 Nm 58 60 Ibf ft When slackening or tightening the track rod end locknuts it is important that the torque reaction is re sisted using the track rod end fiats and...

Page 83: ...he bush should be lubricated on assembly with M0S2 type grease Excessive radial clearance between the bar and bush may cause knocking noises which can be reduced by removing material from the joint face of the split bush to reduce the effective diameter Lower Wishbone Inboard Pivots Early Type Anti Roll Bar Mounting Flanged spacer tube Front eg Rear leg Bonded reinforcement plate Bonded inserts An...

Page 84: ...kets and substituting the new parts including the reshaped anti roll bar Fettling of the crash structure will also be required to provide clearance for the higher mounting position of the new bar Note that smaller washers are used on the clamp bracket upper fixing bolts in order to clear the joint ridge in the chassis extrusion 63 5 mm 52 mm Wishbone pivot hole 10 mm c39 New a r b mounting holes C...

Page 85: ...llies Smear the outer surface of the new bush with IPC P 80 rubber lubricant emulsion A082C6042V to ease fitment and assemble as follows Top wishbone insert from the outside of both pivot eyes from front of front eye and rear of rear eye Lower wishbone insert from the inside of both pivot eyes from rear of front eye and front of rear eye Note that the top wishbone rear bush was originally common w...

Page 86: ...t plinth to hub carrier 45 Steering arm to hub carrier 45 Track rod end to steering arm 30 Damper to lower wishbone 45 Damper to chassis 45 Brake caliper to hub carrier 45 Anti roll bar rubber bush mounting clamps 20 Anti roll bar drop links 45 CG 5 FRONT WHEEL BEARINGS A sealed dual taper roller bearing with a split inner race is retained in each front hub by two circlips The hub is pressed into ...

Page 87: ... 4 Remove the hub clamp bolt and washers noting that LH hub M12 bolts are LH thread M16 bolts are RH thread for both sides and press the hub out of the bearing If necessary use a puller to remove the inner race from the hub spigot 5 Remove both circlips from the hub carrier and press out the bearing 6 Before fitting the new bearing clean any corrosion from the bearing bore outside of the circlip g...

Page 88: ...CG Tighten the hub clamp bolt nut M12 77 Nm M16 210 Nm 8 Re assemble the suspension in reverse order to dis assembly referring also to sub section CG 4 Pump the brake pedal to reposition the pads before driving the car Page 12 1998 03 ...

Page 89: ... General Description Geometry Adjustments Suspension Disassembly Assembly Rear Toe Link Fixings Rear Wheel Bearings Wheel Speed Sensor Barrel Shaped Road Springs Section DE Sub Section I3 age DE 1 3 DE 2 3 DE 3 5 DE 4 8 DE 5 10 DE 6 12 DE 7 12 1998 03 Page 1 ...

Page 90: ... I Lotus Service Notes Section DE Damper clevis Upper ball joint Damper Hub carrier Top wishbone subframe Lower wishbone Driveshaft Toe control link Road spring Lower ball joint Page 2 1998 03 ...

Page 91: ...in side rail Certain components are common with the front suspension and include top and bottom swivel joints hubs and hub bearings and some wishbone pivot bushes DE 2 GEOMETRY ADJUSTMENTS Provision is made for the adjustment of wheel alignment and camber Under normal service conditions no periodic scheduled check of the geometry is necessary with a full geometry check required only after suspensi...

Page 92: ...l link which is equipped with a left hand threaded ball joint at one end and a right hand threaded ball joint at the other Slacken both ball joint locknuts and turn the link rod as necessary to increase or decrease the effective length of the link As a guide lengthening the link rod by a turn of one flat 60 will increase toe in by just less than 1mm After adjustment tighten the two locknuts to 77 ...

Page 93: ...ng is to be removed from the damper unit Removal of the driveshaft from the hub will usually result in separation of the hub bearing two part inner race with likely damage to the integral seal If the hub or hub carrier is being removed for reasons other than for hub bearing replacement the inboard driveshaft should be removed from the transmission and the complete driveshaft assembly retained with...

Page 94: ...ne from the rear subframe 8 Remove the top and bottom mounting bolts for the spring damper unit and withdraw 9 Remove the lower wishbone pivot bolts and withdraw the lower wishbone and toe link 10 If necessary remove the top or bottom swivel joint ball pin nut and use a ball joint splitter tool to separate the joint from its plinth The swivel joint may be replaced using suitable press tool dollies...

Page 95: ...f the hub carrier with any steel component e g swivel joint plinth camber shim plates etc with Duralac MSDS anti corrosive jointing compound A111C6017 and assemble whilst the compound is still tacky The lower ball joint pin must be tightened into the plinth before fitting the plinth to the hub carrier Take care to refit the original camber adjustment shimpack Lubricate the ends of the damper eye b...

Page 96: ...ngth of which are critical to ensure adequate thread engagement without danger of bottoming out in the joint with the length of the outboard bolt dependent on the bump steer shim pack Cars built from December 98 onwards use toe link ball joints with integral studs secured to the chassis and hub carrier with M10 Nyloc nuts The outboard end conical spacer and bump steer shim washers differ for the i...

Page 97: ...asher beneath bolt head A111W4180F 5 shim washers M 10x65 bolt A111D0065F 1 8mm flat washer beneath bolt head A111W4163F Note that the great majority of cars are built with 4 shim washers Assemble the bolt with washers and spacer into the hub carrier and check the following two dimensions i The exposed shank length Specification 1 0 to 9 0 mm ii The exposed bolt length Specification 21 0 to 25 0 m...

Page 98: ...ilt from VIN W 5479 December 98 Cars built from December 98 onwards use toe link ball joints with integral studs secured to the chassis and hub carrier with M10 Nyloc nuts The outboard end conical spacerdiffers from that used for the earlier type joints by featuring an internal chamfer to clear the stud root and by an increased height The shim washers also differ in being of larger diameter to fit...

Page 99: ... result in separation of the hub bearing inner race necessitating renewal of the bearing To Replace Rear Hub Bearing Note that removal of a rear hub Replacement of the hub bearing is most easily performed with the hub carrier removed to a bench Bearing circlips Outboard driveshaft Hub carrier Hub bearing Rear hub Hub nut 1 With the wheel removed apply the parking brake and release the driveshaft t...

Page 100: ...g is inhibited with the hub in place When fitting the plate to the hub carrier ensure that the correct hand of plate is fitted with the extended boss positioned at the outboard top The fixing method of the caliper mounting plate to the hub carrier was changed during 1997 Early type with tapped holes in the hub carrier Apply Permabond A025 high temperature threadlocking compound orange A912E6800V t...

Page 101: ...y fitting shim washers between the sensor fixing tab and the mounting bracket Tighten the sensor fixing screw and bracket fixing screw to 9 3 Nm Ensure that the toothed ring does not become clogged with mud or accumulated dirt DE 7 BARREL SHAPED ROAD SPRINGS In June 98 at approx VIN W 3580 the front and rear road springs were changed from parallel black painted to barrel shaped graphite coloured i...

Page 102: ... and rear damper bodies ii Replace each rear damper top mounting bracket with new bracketA111D0076F together with load spreading plate A111D0125F Discard the plain washers previously used on the fixing bolts New type damper top mount Spreader plate Old type bracket f H t Page 14 1999 0 1 ...

Page 103: ...Section EE ENGINE SECTION EE M111 ELISE General Description Maintenance Operations Engine Removal Replacement Special Tools Sub Section Page EE 1 1 EE 2 1 EE 3 5 EE 4 6 ...

Page 104: ...ping up is necessary remove the oil filler cap from the cam cover and in order to allow the crankcase to venti late remove the dipstick Add a suitable quan tity of a recommended engine oil see Sec tion OG taking care not to spill any oil onto engine or electrical components use a funnel if necessary Oil filler cap The difference between high and low dipstick marks is equivalent to 1 0 litre 1 8 im...

Page 105: ...il Use authorised waste collection facilities including civic amenity sites and garages providing facilities for disposal of used oil and used oil filters If in doubt contact your local authority for advice on disposal Severe Service Conditions Certain operating conditions can cause rapid degradation of the oil quality either by the accumulation of dirt particles or by the absorption of water from...

Page 106: ...ed and each of the pulleys must be thoroughly degreased before the new belt is fitted To replace the belt Slacken the alternator pivot bolt A Slacken the clamping bolt B securing the alternator to the slotted strap Turn the adjuster bolt C in the end of the slotted strap to allow the alternator to be swung towards the engine and unhook the belt from the pulleys Fit the new belt over the two pulley...

Page 107: ... refer to Section BN From beneath the car 3 Drain the coolant and transmission oil 4 Remove the exhaust downpipe between the exhaust manifold and catalytic converter 5 Remove the gear cables from the transmission lever spigots prise off and pull off the spring clips retaining the outer cables to the abutment bracket 6 Release the earth braid from the transmission end case and the throttle cable fr...

Page 108: ...ssary Lubricate the lip of the seal with transmission oil and grease the corresponding shoulder on the driveshaft C V joint spigot to reduce the danger of damaging the seal on assembly Carefully insert the shaft assembly into the transmission with the lubricated circlip fitted on the end of the spigot shaft Press the C V joint into the differential gear splines until a click indicates that the cir...

Page 109: ...s and damp cylinder liners This engine is fitted to the following models MGF Rover 114 and 214 414 New Rover 214 216 218 and BRM New Rover 414 and 416 Coupe Cabriolet Tourer and Sports Models Rover 25 Rover 45 and Rover 75 Publication Part No RCL 0057ENG 5th Edition Published by Rover Technical Communication 2000 Rover Group Limited ...

Page 110: ...INE NUMBER LOCATION 2 ENGINE SERIAL NUMBER PREFIXES 2 COMMENCING ENGINE NUMBERS 2 K16 Non VVC engines fitted with automatic timing belt tensioner 2 K16 Non VVC engines fitted with modified camshafts and cylinder heads 3 Cylinder heads fitted with triple angle valve seats 3 Modified Type B crankshafts 3 ...

Page 111: ...nsions quoted are to design engineering specification with Service limits where applicable During the period of running in from new certain adjustments may vary from the specification figures given in this manual These will be reset by the Dealer at the First Service and thereafter should be maintained at the figures specified in this manual REPAIRS AND REPLACEMENTS When replacement parts are requ...

Page 112: ...51 L64 L67 L68 L69 L82 L97 L98 L99 K79 K80 K88 K89 M01 M21 M22 M23 M26 M27 M28 M29 M30 M31 M36 M37 M38 M39 M41 M42 M47 M48 M49 M50 M51 M52 M53 M54 M55 M56 M62 M64 M65 M67 M68 M70 M71 M72 M73 M75 M76 M79 M80 M81 M82 M83 M84 M85 M86 M87 M88 M89 M90 M91 M92 M93 M94 M95 M96 M97 M98 M99 N01 12M1762 The engine number will be found stamped either on the LH side of the bearing ladder or cast on the rear L...

Page 113: ...4FK80 853676 16K4FL32 6847i 5 16K4FL33 684141 16K4FL34 67489 5 16K4FL35 675041 18K4FJ31 685002 18K4FJ32 678009 18K4FJ78 679210 18K4FJ79 682294 18K4FL66 658261 18K4FL67 615758 18K4KL36 667388 18K4KL37 657611 18K4KJ89 673981 18K4KJ90 637368 INTRODUCTION Modified type B crankshafts 11K2FK42 602582 14K2FH67 601998 14K2FK43 604022 14K2FK44 585572 14K2FL64 589869 14K4FH71 589479 14K4FH72 603771 14K4FK76...

Page 114: ...ENGINE This page is intentionally left blank DESCRIPTION AND OPERATION 111 ...

Page 115: ...INE DESCRIPTION AND OPERATION ...

Page 116: ...ENGINE This page is intentionally left blank DESCRIPTION AND OPERATION 111 ...

Page 117: ...IGINE DESCRIPTION AND OPERATION ...

Page 118: ...housing plastic 51 Oil filter adapter 17 0 ring 52 Gasket 18 Seal thermostat 53 Bolt 19 Thermostat 54 Oil pressure switch 20 Cover plastic 55 Sealing washer 21 Screw 56 Oil temperature sensor if fitted 22 O ring 57 Sealing washer 23 Coolant rail 58 Oil filter element 24 Screw coolant rail 59 Pressed steel sump 25 Vent screw if fitted 60 Gasket 26 Sealing washer 61 Sump bolt M6 Patchlok 27 Cylinder...

Page 119: ...GINE DESCRIPTION AND OPERATION ...

Page 120: ...rrier short 17 Locating dowel camshaft carrier 18 Camshaft 19 Drive pin camshaft gear 20 Camshaft oil seal 21 Hydraulic tappet 22 Collets valve 23 Valve spring cap 24 Valve spring 25 Valve stem oil seal 26 Valve guide 27 Exhaust valve 28 Valve seat insert exhaust 29 Inlet valve 30 Valve seat insert inlet 31 Cylinder head 32 Coolant temperature sensor 33 Coolant outlet elbow 34 Bolt coolant outlet ...

Page 121: ...ENGINE 6 DESCRIPTION AND OPERATION ...

Page 122: ...shaft exhaust 16 Drive pin camshaft gear 17 Drive spindle rotor arm 18 Camshaft oil seal 19 Hydraulic tappet 20 Collets cap 21 Valve spring cap 22 Valve spring 23 Valve stem oil seal 24 Cylinder head 25 Ring dowel cylinder head to camshaft carrier 26 Cylinder head gasket 27 Valve guide 28 Inlet valve 29 Valve seat insert inlet 30 Exhaust valve 31 Valve seat insert exhaust 32 Blanking plate 33 Scre...

Page 123: ...ON AND OPERATION ...

Page 124: ... camshaft 18 Exhaust camshaft 19 Bracket multiplug 20 Bolt multiplug bracket 21 Blanking plate 2 off 22 Bolt blanking plate 0 23 Gasket coolant outlet elbow 24 Coolant outlet elbow 25 Sealing washer 26 Gasket 27 Coolant temperature sensor 28 Bolt coolant outlet elbow 29 Hydraulic tappet 30 Valve spring cap 31 Valve spring 32 Valve stem oil seal 33 Collets 34 Locating dowel 35 Cylinder head 36 Gask...

Page 125: ...ENGINE M12 7257 1 0 DESCRIPTION AND OPERATION ...

Page 126: ...st valve 12 Spark plug cover 39 Valve seat insert exhaust 13 Oil filler cap 40 Valve seat insert inlet 14 Filler cap seal 41 Inlet valve 15 Screw spark plug cover 42 Inlet valve guide 16 Washer 43 Cylinder head gasket 17 Bolt camshaft cover 44 Valve stem oil seal 18 Camshaft cover 45 Valve spring 19 Gasket camshaft cover 46 Valve spring cap 20 Bolt camshaft carrier 47 Collets 21 Camshaft carrier 4...

Page 127: ...wer cover 11 Screw M6 x 16 lower cover 12 Crankshaft pulley 13 Special washer pulley bolt 14 Crankshaft pulley bolt 15 Tensioner pulley and backplate 16 Allen screw tensioner to cylinder head 17 Flange head screw tensioner backplate 18 Tensioner spring 19 Sleeve spring 20 Pillar bolt 21 Camshaft timing belt 22 Crankshaft timing gear 23 Camshaft timing gear 24 Camshaft gear bolt 25 Plain washer 26 ...

Page 128: ... 8 Screw M6 x 16 lower cover 9 Crankshaft pulley 10 Special washer pulley bolt 11 Crankshaft pulley bolt 12 Camshaft timing belt 13 Camshaft timing gears 14 Camshaft gear bolt 15 Plain washer 16 Tensioner pulley and backplate 17 Allen screw pulley 18 Tensioner spring 19 Sleeve spring 20 Pillar bolt 21 Flange head screw tensioner backplate 22 Crankshaft timing gear 23 Rear cover timing belt 24 Scre...

Page 129: ...M6 lower cover 8 Screw M6 x 16 lower cover 9 Crankshaft pulley 10 Special washer pulley bolt 11 Crankshaft pulley bolt 12 Camshaft timing belt 13 Camshaft timing gears 14 Camshaft gear bolt 15 Plain washer 16 Bolt tensioner 17 Tensioner 18 Index wire 19 Pointer 20 Pillar bolt 21 Crankshaft timing gear 22 Screw rear cover 23 Screw rear cover to coolant pump 24 Rear cover New Patchlok bolt must be u...

Page 130: ...timing belt 11 Front inlet camshaft timing gear 12 Screw timing belt rear cover 13 Timing belt rear cover 14 Exhaust camshaft front timing gear 15 Crankshaft timing gear 16 Seal lower front cover 17 Lower front cover 18 Screw lower front cover 19 Crankshaft pulley 20 Crankshaft pulley bolt and washer 21 Seal upper front cover These items are not fitted on production but are supplied with replaceme...

Page 131: ...t cover 3 Rear timing belt 4 Bolt M8 rear timing gear 5 Washer rear timing gear bolt 6 Exhaust camshaft rear timing gear 7 Rear timing belt backplate 8 Bolt rear timing belt backplate 9 Rear inlet camshaft timing gear 10 Washer rear timing gear bolt 11 Bolt M10 rear timing gear DESCRIPTION AND OPERATION 111 ...

Page 132: ...ation is by means of a flange which also controls camshaft end float K16 engine The cross flow cylinder head is based on a four valve central spark plug combustion chamber with the inlet ports designed to induce swirl and control the speed of the induction charge This serves to improve combustion and hence fuel economy performance and exhaust emissions The twin overhead camshafts operate the valve...

Page 133: ...d profile on the valve stem removes any build up of carbon in the combustion chamber end of the valve guide thereby preventing valves from sticking These valves may be fitted to all early engines The stainless steel cylinder head gasket has moulded seals around all coolant breather and oil apertures and has steel cylinder bore eyelets Compression of the gasket is controlled by limiters at each end...

Page 134: ...ENGINE DESCRIPTION AND OPERATION 19 ...

Page 135: ...ENGINE K16 engine lubrication system 12M1758A Non VVC camshafts illustrated DESCRIPTION AND OPERATION 20 ...

Page 136: ...ain bearings carry the oil to the big end bearings A passage in the oil pump housing connects to a drilling 8 in the cylinder block to oilways 9 in the cylinder head K8 engine Oil is fed through the cylinder head to a drilling 10 in the one piece camshaft carrier to supply oil to each hydraulic tappet and camshaft bearing k16 engine Oil is fed through the cylinder head to twin full length oilways ...

Page 137: ... ENGINES FITTED WITH MANUAL TIMING BELT TENSIONER 13 TIMING BELT COMPONENTS K16 NON VVC ENGINES FITTED WITH AUTOMATIC TIMING BELT TENSIONER 14 FRONT TIMING BELT COMPONENTS K16 VVC ENGINES 15 REAR TIMING BELT COMPONENTS K16 VVC ENGINES 16 OPERATION 17 OVERHAUL CAMSHAFT TIMING BELT K8 ENGINES 1 CAMSHAFT TIMING BELT K16 ENGINES 4 OIL PUMP 15 COOLANT PUMP 19 THERMOSTAT 20 FLYWHEEL AND STARTER RING GEA...

Page 138: ...lt lower cover 1 Slacken bottom bolt securing timing belt upper front cover NOTE Remove bottom bolt when cover is not slotted 2 Remove 6 bolts from timing belt upper front cover 3 Remove timing belt upper front cover and seal ISO 1571 6 Position flywheel locking tool 18G 1571 to flywheel 7 Secure with 2 bolts 12M0556 4 Rotate crankshaft clockwise to align camshaft gear timing marks with top face o...

Page 139: ... in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the belt 2 Check correct alignment of timing marks for 90 BTDC Crankshaft gear dots align with flange on oil pump Camshaft gear mark torightaligns with top face of cylinder head 12M3756 3 Slacken tensioner b...

Page 140: ...backplate screw and check that belt is being tensioned by the tensioner spring 18 Tighten tensioner backplate screw to 10 Nm and tensioner pulley Allen screw to 45 Nm 19 Ensure inserts are fitted in timing belt upper front cover 20 Fit timing belt upper front cover ensuring correct position of seals tighten screws and bolt to 5 Nm 12M3757 11 Fit crankshaft pufley 10 crankshaft timing gear ensuring...

Page 141: ...d all VVC engines Type B is an automatic tensioner fitted to some K16 non VVC engines Commencing engine numbers for the automatic tensioner are listed in Information The tensioners and their timing belts are not interchangeable The manual timing belt tensioner spring fitted to K16 non VVC engines is fitted with a sleeve whilst on VVC engines only a spring is fitted 6RM0578 4 1 Slacken Dottom bolj ...

Page 142: ...ockwise to align camshaft gear timing marks 90 BTDC CAUTION Do not use camshaft gears gear retaining bolts or timing belt to rotate crankshaft 4 Fit camshaft gear locking tool 18G 1570 18G1674 M124937 8 Fit flywheel locking tool 18G 1674 tighten bolt CAUTION Ensure tooth on tool 18G 1674 j engages with teeth on flywheel not the reluctor ring M124954 5 Check that timing mark on crankshaft pulley is...

Page 143: ...ioner pulley Allen screw 13 Slacken tensioner backplate screw 14 jPush tensibner pulley dqwn to fully OFF i position V k NOTE VVC engines Tensioner spring and pMlar bolt are only fitted for tensioning replacement timing belts 15 Tighten backplate screw to 10 Nm 16 Ease timing belt from gq rs using the fingers pnly v 17 Discard timing belt yv CAUTION Timing belt must always be replaced during engin...

Page 144: ...ust be soaked in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the belt M124962 3 Check that crankshaft gear timing marks are aligned with flange on oil pump 90 BTDC Flywheel not fitted with a reluctor ring 18G1571 4 Fit flywheel locking tool 18G 1571 secur...

Page 145: ...2 NOTE Non VVC camshaft timing gears and tensioner spring illustrated Slacken tensioner backplate screw ensure tensioner moves fully through its adjustment range and returns under spring tension Push tensioner down to fully OFF position tighten tensioner backplate screw to 10 Nm Using the fingers only fit a new timing belt over crankshaft timing gear and then over camshaft gears keeping belt taut ...

Page 146: ...ing belt by applying finger pressure to tensioner backplate 17 With tensioner pulley against timing belt and backplate held in position tighten backplate screw to 10 Nm 18 Rotate crankshaft clockwise 2 complete revolutions and align camshaft gear timing marks CAUTION Do not use camshaft gears j gear retaining bolts or timing belt to rotate crankshaft 19 Slacken tensioner backplate screw and check ...

Page 147: ... bottom bolt to 5 Nm Camshaft timing belt automatic tensioner remove CAUTION Timing belts fitted to engines with automatic timing belt tensioners are not interchangeable with those fitted to engines with manual tensioners M124951 1 Slacken but do not remove bolt securing bottom of timing belt upper front cover 2 3 NOTE Remove bolt when cover is not slotted Noting fitted position of longest screw r...

Page 148: ...s or timing belt to rotate crankshaft M124949 6 Check that timing mark on crankshaft pulley is aligned with mark on timing belt lower cover 18G1674 M124937 5 Fit camshaft gear locking tool 18G 1570 7 Fit flywheel locking tool 18G 1674 tighten bolt CAUTION Ensure tooth on tool 18G 1674 j engages with teeth on flywheel not the reluctor ring OVERHAUL 11 ...

Page 149: ...fitted Camshaft timing belt automatic tensioner refit CAUTION If the sintered gears have been j subjected to prolonged oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitting Because of the porous construction of sintered material oil impregnated in the gears will emerge and contaminate the belt 1 Clean timing gears coolant pump drive ge...

Page 150: ...ley and coolant pump drive gear ensuring that the belt run between the crankshaft gear and the exhaust camshaft gear is kept taut Check that timing belt is positioned centrally around gears and tensioner pulley Ensure inserts are fitted in timing belt lower cover M124953 10 Fit timing belt lower cover ensuring correct position of seals fit screws and tighten to 9 Nm 11 Fit crankshaft pulley to cra...

Page 151: ... gear retaining bolts or timing belt to rotate crankshaft 17 Check that pointer is still correctly aligned with index wire CAUTION If pointer is not correctly aligned carry out the following procedure A 18 Slacken tensioner bolt until it is just possible to move the tensioner lever Using a 6 mm Allen key rotate tensioner lever clockwise until pointer is just above the index wire then rotate tensio...

Page 152: ...ottom bolt to 5 Nm OIL PUMP Remove 1 Remove and discard camshaft timing belt 2 Remove crankshaft timing gear 12M1765 3 Noting fitted position of M6 x 20 bolt A remove and discard 9 bolts securing oil pump to cylinder block 12M1766 4 Remove oil pump assembly NOTE Dowel located 5 Remove and discard oil pump gasket 6 Remove and discard crankshaft front oil seal OVERHAUL 15 ...

Page 153: ... No 820000 all have a 12 mm diameter oil feed hole with an 8 mm diameter offset counterbore B in illustration Later type oil pumps may be fitted as replacements to all engines but early type pumps may not be fitted to engines from Engine No 820000 4 Remove all traces of Loctite from cover plate securing screws and tapped holes in oil pump body ensure screw holes are clean and dry 8RM 3468 3 Check ...

Page 154: ... as an assembly if scoring of plunger is evident or free length of spring is less than specified Replace oil pump if relief valve bore is scored 5 Remove all traces of Loctite from plug and threads in relief valve bore 1 Ensure outer rotor identification marking faces outward 2 Lubricate pump rotors with engine oil 3 Lubricate a new cover plate seal with engine oil 4 Fit cover plate seal and cover...

Page 155: ...ll assist in locating oil pump inner rotor 8 Ensure oil seal protector sleeve is located over end of crankshaft 9 Position new crankshaft front oil seal on crankshaft against oil pump housing Drift seal into position using tool 18G 1587 CAUTION Oil seal must be fitted dry 10 Remove tool 18G 1587 and oil seal protector sleeve 11 Clean crankshaft timing gear 12 Fit crankshaft timing gear 13 Fit and ...

Page 156: ...s and rear cover 6 Remove coolant pump 7 Remove and discard O ring from pump Inspection 11 1 Check for movement of pump spindle in bearing and for coolant leakage from seal Refit 1 Clean pump mating face and dowels 2 Fit new O ring to coolant pump use RTV sealant to retain O ring 3 Fit coolant pump to cylinder block fit bolts and pillar bolt s and tighten in sequence shown to 10 Nm 4 Rear cover fi...

Page 157: ...rings with silicone grease and fit to thermostat housing and cover 3 Fit a new seal to thermostat 4 Align and fit thermostat to shoulder in thermostat housing 5 Fit cover to thermostat housing fit and tighten bolts to 8 Nm CAUTION Torque figure must not be exceeded A 6 Fit thermostat housing to coolant pump align dipstick tube bracket fit and tighten bolt to 10 Nm Connect coolant rail to thermosta...

Page 158: ...lustrated 2 Remove and discard 6 bolts securing flywheel 3 Using assistance remove flywheel trom crankshaft M124937 A NOTE Dowel located 1 Fit flywheel locking tool Flywheel without reluctor ring use 18G 1571 Flywheel with reluctor ring use 18G 1674 CAUTION Ensure tool engages teeth on l flywheel not the reluctor ring A 21 OVERHAUL ...

Page 159: ...e 2 Allow ring gear to air cool 3 Fit flywheel Flywheel refit CAUTION Flywheels fitted to VVC engines j have a reluctor ring with 4 teeth at unequally spaced intervals missing whilst flywheels fitted to engines with plug top coil ignition have reluctor rings with equally spaced teeth If the flywheel is to be replaced it is essential that the replacement is of the correct type 1 Clean flywheel and ...

Page 160: ...will contact the valves A 2 Disconnect tensioner spring remove pillar bolt screw tensioner and spring 3 Disconnect ht leads from spark plugs 5 Using sequence shown progressively slacken and remove 12 bolts securing camshaft cover 6 Remove camshaft cover discard gasket 8 R M 3516 7 Mark distributor flange for refitting reference 8 Remove 2 screws securing distributor 9 Remove distributor discard O ...

Page 161: ...ing sequence shown progressively slacken 10 cylinder head to oil rail bolts Remove bolts and store in fitted order CAUTION Removal of cylinder head bolts j will result in a tightening up of the crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G 1736 are fitted 17 Using assistance remove cylinder head assembly CAUT...

Page 162: ...ocation Cylinder head K16 Non VVC engines fitted with distributor remove CAUTION If crankshaft is to be removed l during overhaul it will be necessary to check and record crankshaft end float prior to removing cylinder head 18G 1570 2 M124930 1 Remove and discard camshaft timing belt CAUTION Do not rotate crankshaft whilst timing belt is removed and cylinder head is fitted pistons will contact the...

Page 163: ...illar bolts have been replaced b y cast in supports which are an integral part of the camshaft cover 8RM 3521A 10 Release 2 screws and remove distributor cap 11 Remove and discard screw securing rotor arm 12 Remove rotor arm 13 Remove anti flash shield M124973 A NOTE Later engines are fitted with modified camshafts which incorporate a reluctor ring and the procedure for removing cylinder head bolt...

Page 164: ...urn both camshafts clockwise to gain access to bolts Early engines bolts 9 and 10 Later engines fitted with modified camshafts bolts 7 and 8 Progressively slacken then remove the remaining bolts and store in fitted order CAUTION Removal of cylinder head bolts l results in a tightening up of crankshaft rotation of crankshaft must therefore be kept to a minimum Do not rotate crankshaft until cylinde...

Page 165: ...r head bolts into oil rail and tighten sufficiently to A retain clamps CAUTION Ensure that bolts used are those originally fitted in that location NOTE This is the longest of the rear cover securing screws 20 Remove timing belt tensioner pillar bolt 21 Using assistance remove cylinder head assembly from cylinder block CAUTION Cylinder head is dowel located j do not tap it sideways to free it from ...

Page 166: ... will contact the valves a M124950 M124959 2 Noting that shortest screw is fitted in centre of spark plug cover remove 3 screws securing cover to camshaft cover 3 Remove spark plug cover 4 Disconnect ht lead and plug tube from No 4 spark plug 5 Remove 2 bolts securing front coil to camshaft cover 6 Carefully raise coil until plug tube is disconnected from No 1 spark plug disconnect multiplug from ...

Page 167: ...move any debris from spark plug recesses remove 4 spark plugs 18 Progressively slacken then remove 15 bolts securing camshaft cover 19 Remove camshaft cover remove and discard gasket 20 Check and record crankshaft end float 8RM 0740 21 Using sequence shown progressively slacken cylinder head bolts 1 to 6 A NOTE It will be necessary to carry out the following operations in order to remove the remai...

Page 168: ...tightening up of crankshaft rotation of crankshaft must therefore be A kept to a minimum Do not rotate crankshaft until cylinder liner retainer clamps 18G1736 are fitted 26 Suitably identify each camshaft gear to its respective camshaft and using tool 12 182 to hold camshaft gear against rotation remove bolt and plain washer from each camshaft gear 27 Remove camshaft gears 29 Remove screws securin...

Page 169: ... to be removed l during overhaul it will be necessary to check and record crankshaft end float a prior to removing cylinder head 1 Remove and discard camshaft timing belt CAUTION Do not rotate crankshaft whilst I timing belt is removed and cylinder head is fitted pistons will contact the valves a 12 182 M124932A 2 Ensure that tool i G 1570 is fitted to c mshaft gears 3 Suitably identify each camsh...

Page 170: ... 12 Remove bolt securing camshaft sensor remove sensor 13 Remove and discard O ring 14 Release harness from clip A NOTE Camshaft cover fitted to early engines illustrated 6 Remove 2 screws securing spark plug cover 7 Remove spark plug cover 8 Disconnect 4 plug tubes from spark plugs 9 Remove any debris from spark plug recesses 10 Remove and discard 4 spark plugs 11 Release HT leads from camshaft r...

Page 171: ...12M1770 22 Assemble cylinder retainer clamps 18G 1736 to cylinder head bolts Position retainer clamps on cylinder liners ensuring that clamps do not protrude over liner bores Screw cylinder head bolts into oil rail and tighten sufficiently to retain clamps CAUTION Ensure that bolts used are those originally fitted in that location A 18 Using sequence shown progressively slacken then remove 10 cyli...

Page 172: ...afts 12M3493 1 Assemble a suitable DTi to camshaft carrier with stylus of gauge contacting face of front camshaft number 4 cam 2 Move camshaft fully rearwards and zero gauge 3 Move camshaft fully towards and note end float reading on gauge Inlet camshaft end float 0 03 to 0 15 mm Service limit 0 25 mm 4 Repeat above procedure for rear camshaft with stylus of gauge contacting face of number 5 cam 5...

Page 173: ...all K16 Non WC engines remove K8 1 Using sequence shown progressively slacken 22 bolts securing camshaft carrier to cylinder head until valve spring pressure is released remove bolts 12M1994 2 Remove camshaft carrier NOTE Dowel located A 3 Remove camshaft 4 Remove and discard camshaft oil seals 5 Using a stick magnet remove 8 tappets from cylinder head Retain tappets in their fitted order and inve...

Page 174: ...ear of camshaft carrier remove plate A NOTE On engines fitted with plug coil ignition blanking plates are fitted for both inlet and exhaust camshafts 7 Using sequence shown progressively slacken 26 bolts until valve spring pressure is released Remove bolts 8 Remove camshaft carrier NOTE Dowel located 9 Suitably identify each camshaft to its fitted position remove camshafts 10 Remove and discard oi...

Page 175: ...ify each rear camshaft gear to its respective camshaft 4 Using tool 12 182 restrain rear inlet camshaft timing gear and remove bolt and washer retaining gear 5 Repeat above procedure for exhaust camshaft rear timing gear 6 Remove tool 12 182 from gear 7 Remove both rear timing gears from camshafts remove and discard rear timing belt CAUTION Rear timing belt must always be replaced during engine ov...

Page 176: ...bolts securing each VVC housing to cylinder head 20 Slacken 2 bolts securing each VVC housing to camshaft carrier by 1 turn ACAUTION Do not exceed 1 turn 2 2 2 7 2 6 3 2 18G1299 A1 I 12M3494 21 Using sequence shown progressively slacken and noting the position of 4 longest bolts remove 32 bolts securing camshaft carrier to cylinder head 14 Fit camshaft gear bolt to front VVC mechanism 15 Screw too...

Page 177: ...mshaft carrier A NOTE Bolts should only be slackened sufficiently to enable timing plates 18G 1770 1 and 18G 1770 2 to be fitted 22 Ensunng that front and rear inlet camshafts are retained in camshaft carrier and VVC assemblies carefully release camshaft earner from cylinder head NOTE Dowel located 23 Lift camshaft carrier together with front and rear inlet camshafts off cylinder head CAUTION Ensu...

Page 178: ...o camshaft carrier 30 Remove front and rear camshafts together with VVC assemblies ACAUTION Oo not remove clamps 18G 1770 31 Remove control shaft from camshaft carrier Ml24973 CAUTION In order to commonise exhaust camshafts between VVC and non VVC engines modified exhaust camshafts incorporating a reluctor ring are fitted to later engines these camshafts are not interchangeable with those fitted t...

Page 179: ...s for wear pitting and scoring replace components as necessary Non VVC engines CAUTION A modified tappet has been l introduced and will be supplied as a replacement for all non VVC engines The above illustration show the early tappet A and modified tappet B When the modified tappets are already fitted to an engine they may be replaced on an individi al basis but may only be fitted as replacements ...

Page 180: ...be fitted ensure they are correct for engine being worked on A Checking camshaft bearing clearance Non VVC engines K8 12M0563 K16 Position camshaft s in cylinder head and place Plastigage across each journal Fit camshaft carrier and tighten bolts in sequence shown to 10 Nm Do not rotate camshaft s Progressively slacken bolts and then remove camshaft carrier 8RM 3526 7 Remove drive pin from old cam...

Page 181: ...ent Camshafts and timing gears K16 VVC engines inspection Camshafts A NOTE Carry out camshaft inspection alter removal of valves 1 Clean camshaft carrier and cylinder head bearing surfaces use suitable solvent to remove sealant CAUTION Do not remove clamps 18G 1770 whilst cleaning or inspecting inlet camshafts A 2 Inspect cams and bearing journals for wear pitting and scoring replace components as...

Page 182: ...er head 32 27 21 28 22 17 12 12M3503 8 Fit 32 bolts noting that 4 longest bolts are fitted at each end of camshaft carrier 9 Using sequence shown progressively tighten bolts 10 Nm A CAUTION Do not rotate camshafts 10 Progressively slacken then remove 32 bolts securing camshaft carrier to cylinder head 11 Carefully release camshaft carrier from cylinder head 12 Lift camshaft carrier together with f...

Page 183: ...retain clamps 15 Remove slave bolts securing VVC housings to camshaft carrier 16 Remove front and rear inlet camshafts and VVC housings from camshaft carrier CAUTION If new VVC housing gaskets j have been fitted do not remove timing plates 18G 1770 1 and 18G 1770 2 12M3442A 18 Measure widest portion of Plastigage on each exhaust camshaft journal Exhaust camshaft bearing clearance 0 060 to 0 094 mm...

Page 184: ...t from cylinder head 21 Remove all traces of Plastigage using an oily rag Timing gears VVC engines CAUTION If gears have been subjected to prolonged exposure to oil contamination they must be soaked in a solvent bath and then thoroughly washed in clean solvent Ensure reference marks are not erased 1 Clean timing gears check gear teeth for damage and drive pin slot for wear replace gears as necessa...

Page 185: ... engine Remove inlet valves with cylinder head in this position 180 1519 1 8RM3627 A NOTE K16 Non VVC cylinder head illustrated 16G 1519 8RM 0075 6 Remove spring cap and valve spring 7 Remove valve A NOTE K1S Non VVC cylinder head illustrated 3 Using tool 18G 1519 and adapter 18G 1519 1 compress valve spring 4 Remove 2 collets from valve stem using a magnet 5 Remove tool 18G 1519 4 8 OVERHAUL ...

Page 186: ...oil drain hole drilled through the head from the camshaft oil seal recess ensure drilling is clear 4 K8 engine Check fuel pump blanking plate if fitted for signs of oil leakage Replace gasket if necessary tighten blanking plate nuts to 25 Nm 8HM 0066 8 Using 18G 1577 remove and discard valve stem seal 9 K8 Repeat above operations to remove all remaining valves K16 Repeat above operations to remove...

Page 187: ...CAUTION Cylinder heads fitted to K16 l engines with automatic timing belt tensioners are not interchangeable with those fitted to engines with manual tensioners A NOTE Valve springs are either colour coded or plain K8 Yellow red K16 Non VVC engines Plain K16 VVC engines Blue KB Free length 46 2 mm Fitted length 37 0 mm Load valve closed 255 12 N Load valve open 535 20 N K16 Non VVC engines Free le...

Page 188: ...ures 5 Insert valve into its respective guide 6 Extend valve head 10 mm out of valve guide and position suitable DTI gauge to rear of valve head 7 Move valve towards front of cylinder head pre load gauge to valve head then zero gauge 8 Move valve towards rear of cylinder head record reading obtained to give valve stem to guide clearance B 9 Repeat above procedures for each valve in turn 1 Remove c...

Page 189: ...de diameter B 6 000 to 6 025 mm Valve stem to guide clearance C Inlet 0 033 to 0 063 mm Service limit 0 07 mm Exhaust 0 038 to 0 078 mm Service limit 0 11 mm 18G 1576 1 18Q 1576 3 8RM 0077 A 10 Renew valves and guides as necessary 2 Position tool guide 18G 1576 3 in tappet bore and drift out valve guide using tool dnft 18G 1576 1 NOTE Retain valve guides in their fitted order A B C D 12M0007 3 Ide...

Page 190: ...depth gauge contacts top of valve guide bore CAUTION Triple angle valve seat inserts l have been introduced on later K16 dSengines these inserts are not interchangeable with those fitted to early engines Commencing engine numbers for engines fitted with the new inserts are listed in Information 1 Renew valve seat inserts as necessary CAUTION Do not damage counterbore when removing insert 2 Cool re...

Page 191: ...1102A Inlet A 27 38 to 27 62 mm B 29 40 to 29 80 mm C 32 56 to 32 57 mm D 18 to 20 E 32 475 to 32 500 mm F 5 95 to 6 00 mm G 6 46 to 6 62 mm H 7 00 mm radius J 0 74 to 1 25 mm K 44 to 46 Exhaust A 23 68 to 23 93 mm B 24 80 to 25 20 mm C 28 99 to 29 00 mm D 11 to 13 E 28 88 to 28 91 mm F 5 45 to 5 50 mm G 6 00 to 6 16 mm H 6 0 mm radius J 0 75 to 1 25 mm K 44 to 46 Inlet A 22 98 to 23 13 mm B 25 73...

Page 192: ... Exhaust A 15 B 45 C 60 D 0 4 mm radius E 28 993 to 29 006 mm F 1 4 to 1 8 mm G s 26 23 mm H 28 888 to 28 913 mm J 5 45 to 5 50 mm K 6 54 mm All engines Inlet A 15 B 45 C 60 D 0 4 mm radius E 29 560 to 29 573 mm F 1 0 to 1 4 mm G 26 43 mm H 29 475 to 29 500 mm J 5 95 to 6 00 mm K 6 16to 6 32 mm 1 Cut valve seat to correct angle and width 2 Lap valve to seat Exhaust A 15 B 45 C 60 D 0 4 mm radius E...

Page 193: ...15 Triple angle valve seats only MS76 111 60 To narrow valve seats and obtain seat widths MS76 122 45 Make final cut and remove any burrs Valve seat Angle 45 Width A Except triple angle valve seats Inlet 1 5 mm Exhaust 1 5 mm Triple angle valve seats Inlet 1 0 to 1 4 mm Exhaust 1 4 to 1 8 mm Valve face angle B Inlet 45 Exhaust 45 K8 8 R M 3531 5 Check valve stem fitted height A New 38 95 to 40 81 ...

Page 194: ...d Taking care not to allow camshaft to become separated from VVC mechanism remove clamp 18G 1770 and timing plate 18G 1770 1 front or 18G 1770 2 rear Remove and discard VVC housing gasket Repeat above procedures for remaining VVC housing gasket 1 Lubricate sealing ring of new gasket with engine oil 3 4 5 6 18G1770 12M3499 2 Fit timing plate 18G 1770 1 front or 18G 1770 2 rear Fit gasket align bolt...

Page 195: ... valve 7 Withdraw piston and rack assembly 1 Check piston and spool valve bores in hydraulic control unit for scoring and corrosion replace control unit if scoring is evident 2 Check piston for scoring A NOTE Light scoring and corrosion may be removed using grade 600 grade wet or dry paper which has been soaked in engine oil for 30 minutes 3 Check rack teeth for signs of wear or damage replace hyd...

Page 196: ... 3 Using the fingers only fit labyrinth seals each side of hydraulic control unit seal plate y CAUTION Ensure seals are located beneath retaining lugs 4 Fit new rack seal to plate 6 Secure rack in a soft jawed vice fit new piston and seal assembly to rack fit and tighten new screw supplied with seal kit to 9 Nm Lubricate piston bore with engine oil Position seal plate piston and rack assembly to h...

Page 197: ...it to each side of spool valve nut washer inner solenoid and sleeve bolt side of outer solenoid 12 Lubricate spool valve and bore in control unit with engine oil 13 Position spool valve to control unit fit valve twisting it slightly as it is inserted to avoid damaging O rings 14 Tighten spool valve nut to 26 Nm 15 Position inner solenoid on spool valve ensuring that lettering on end of solenoid is...

Page 198: ... fitted in camshaft carrier 2 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on camshaft carrier as shown and spread to an even film using a roller CAUTION Ensure sealant does not enter lubrication grooves on camshaft carrier and that assembly is completed within 20 minutes 3 Lubricate camshaft cams and journals with engine oil 12M0563 4 Fit camshaft carrier fit and light...

Page 199: ...haft carrier and oil seals All K16 Non VVC engines refit 1 Ensure 2 locating dowels are fitted in camshaft carrier 12M3523 2 2 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on cylinder head as shown then spread to an even film using a roller CAUTION Ensure sealant is kept clear of j tappet oil feed holes and lubrication grooves in carrier and that assembly is completed w...

Page 200: ...ctly within recess 7 Fit blanking plate s fit and tighten bolts to Inlet camshaft plate Plug top coil ignition engines only 6 Nm Exhaust camshaft plate All engines 25 Nm Camshaft carrier and camshafts K16 VVC engines refit 1 Ensure 2 locating dowels are fitted in camshaft carrier 2 Fit new VVC housing gaskets 12M3500 3 Lubricate exhaust camshaft cams and journals with engine oil position camshaft ...

Page 201: ... position VVC assemblies and shaft as necessary until alignment is correct 10 Remove clamps 18G 1770 CAUTION Do not remove timing plates at j this stage or damage to VVC housing seals will result M124948 11 Apply continuous thin beads of sealant Part Number GUG 705963GM to paths on cylinder head as shown then spread to an even film using a roller CAUTION Ensure that sealant is kept j clear of oil ...

Page 202: ...seal protector 18G 1749 over end of camshaft and fit new exhaust camshaft front and rear oil seals using tool 18G 1769A A NOTE Front oil seals are coloured BLACK rear oil seals are coloured RED CAUTION Oil seals must be fitted dry Do not use tool 18G 1769 for fitting seals as they will not be positioned correctly within recess 18G 1604A M12 7255 19 Fit new front and rear VVC housing oil seals usin...

Page 203: ... timing slots are not visible carry out following procedure A 25 Remove hydraulic control unit 21 Ensure that hydraulic control piston is pushed fully to top of bore and that rack teeth will be aligned to control shaft when control unit is fitted 22 Position hydraulic control unit and seal plate to camshaft carrier engage teeth of rack with those of control shaft 23 Fit and lightly tighten 3 bolts...

Page 204: ...and lightly tighten 3 bolts 29 Check that timing slots on both Iront and rear VVC control sleeves are visible If slots are still not visible repeat the foregoing procedure as necessary 30 Apply low pressure air to oil temperature transmitter port in hydraulic control unit to extend rack 31 Check that rack is fully extended i e rack teeth are at limit of travel and timing slots are no longer visibl...

Page 205: ...tighten bolt 38 Using tool 12 182 rotate both timing gears until timing marks on gears are facing outwards 39 Check alignment of timing marks using a straight edge A NOTE With timing marks in this position the lobes of numbers 3 4 5 and 6 inlet cams will be facing upwards 40 Remove bolt and withdraw rear inlet camshaft gear sufficiently to enable a new rear timing belt to be fitted fit rear timing...

Page 206: ...ng gears to their respective camshafts rotate gears until timing marks on all 4 gears are aligned facing inwards fit tool 18G 1570 43 Check alignment of each pair of timing marks in turn using a straight edge 44 Remove tool 18G 1570 and front timing gears 12M3515 45 Fit rear timing belt cover fit and tighten screws to 10 Nm OVERHAUL 6 9 ...

Page 207: ...e cylinder liner retainer clamps 18G 1736 CAUTION Do not rotate crankshaft until cylinder head bolts are fitted 5 Fit new cylinder head gasket DRY with identification markings facing upwards on to cylinder block CAUTION Take care not to damage sealing faces of gasket 8 Tighten cylinder head bolts progressively in sequence shown to 20 Nm Use a felt tip pen and mark position of radial mark on each b...

Page 208: ...of radial mark on each bolt head Tighten all 10 bolts in sequence shown through 180 Tighten all bolts in sequence shown through another 180 and align mark CAUTION If any bolt is overtightened back off 90 and re align 11 Upon completion of tightening sequence position camshafts with inlet pin at 4 o clock and exhaust pin at 8 o clock remove timing gears CAUTION Ensure camshafts do not rotate when g...

Page 209: ...owels are fitted in cylinder block 3 Oil cylinder head bolts under heads and threads of bolts 4 Remove cylinder liner retainer clamps 18G 1736 A CAUTION Do not rotate crankshaft until cylinder head bolts are fitted 5 Fit new cylinder head gasket DRY with identification marks facing upwards on to cylinder block a 6 7 CAUTION Take care not to damage sealing faces of gasket Using assistance fit cylin...

Page 210: ...60 A CAUTION If any bolt is overtightened back off 90 and re align 9 Fit camshaft cover and timing gears 10 Fit new spark plugs tighten to 25 Nm 2 Position camshaft cover on cylinder head 3 Fit bolts and tighten progressively in sequence shown to 10 Nm 4 Position timing belt upper rear cover to cylinder head fit screws and tighten to 9 Nm A NOTE Longest screw secures cover to coolant pump 12M0557A...

Page 211: ... shown to 10 Nm Camshaft cover with cast in supports All camshaft covers 5 Non VVC engines Fit air cleaner support bracket tighten bolts to 10 Nm 6 Locate HT leads in clips and press plug tubes on to spark plugs 7 Fit spark plug cover to camshaft cover tighten screws to 10 Nm 8 Position timing belt upper rear cover to cylinder head fit screws and tighten to 9 Nm A NOTE Longest screw secures cover ...

Page 212: ...ming gears K16 engines fitted with plug top coil ignition system refit 1 Clean mating surfaces and inside of camshaft cover If necessary wash oil separator element in suitable solvent and blow dry 2 Fit new camshaft cover gasket dry to camshaft carrier with either TOP mark towards the inlet manifold or EXHAUST MAN SIDE towards exhaust manifold M124976 3 Fit camshaft cover on to camshaft carrier fi...

Page 213: ...nsioner refit A NOTE On engines fitted with an automatic tensioner tensioner is fitted when timing belt is fitted A NOTE K16 non VVC engine illustrated On VVC engines tensioner spring and pillar bolt are supplied with replacement timing belt 1 Fit timing belt tensioner and pillar bolt tighten bolt to 25 Nm 2 Connect tensioner spring to tensioner and pillar bolt CAUTION E n s u r e correct s p r i ...

Page 214: ... engines if fitted refit KB 1 Fit new O ring to distributor 2 Position distributor and turn rotor to engage offset drive align reference mark or centralise distributor and lightly tighten screws 3 Fit distributor cap and connect plug leads K16 4 Fit anti flash shield and rotor arm Use new rotor arm screw and tighten to 10 Nm 5 Fit distributor cap assembly 6 Place HT lead retaining plate and gromme...

Page 215: ... immediately bolt test is completed Take great care not to rotate crankshaft or disturb cylinder liners whilst clamps are removed 2 Measure distance from cylinder block face to under bolt head A in illustration 97 mm or less bolt may be re used Over 97 mm new bolt must be used Test with oil rail removed 1 Ensuring cylinder head bolts are in their original fitted location screw each bolt by hand in...

Page 216: ...re obtained 1 Remove flywheel 2 Remove tool 18G 1571 3 Remove and discard camshaft timing belt 5 8RM 3480B 4 Withdraw dipstick 5 Remove 3 screws and dipstick tube discard gasket 6 Remove cylinder head assembly a 7 8 CAUTION Ensure cylinder liner retainer clamps 18G 1736 are fitted Remove oil pump Using assistance position cylinder block cylinder head face down on 2 wooden blocks CAUTION Ensure tha...

Page 217: ...ing sump to bearing ladder noting the fitted position of 2 M8 x 60 bolts 15 Using a mallet gently tap sump sideways to release sealant bond remove sump CAUTION Do not Iever between sump j flange and bearing ladder 16 Temporarily remove cylinder retainer liner clamps 18G 1736 CAUTION Do not rotate crankshaft until j retainer clamps are refitted 12M1996 17 Remove 2 screws suction pipe to oil rail 18...

Page 218: ...o BDC A CAUTION Crankshaft will be tight do not rotate crankshaft more than absolutely necessary 5 Make cylinder number reference mark on big end bearing caps A NOTE Number stamped below cap joint is bearing bore size code Number stamped on connecting rod is cylinder number and letter is weight code 6 Remove 4 dowel bolts and 2 big end bearing caps from Numbers 2 and 3 connecting rods keep dowel b...

Page 219: ...lts A are under the flanges of the rear mounting brackets Also note position of flange d head longer bolt 6 at front end of ladder 12M1777 5 Remove bearing ladder 6 Remove and discard main bearing shells from bearing ladder 12M1778 7 Using assistance lift crankshaft from cylinder block 8 Remove and discard crankshaft rear oil seal 9 Remove 2 thrust washer halves from Number 3 bearing position CAUT...

Page 220: ...earing CAUTION Crankshafts fitted to later engines have increased main journal diameters Commencing engine numbers for the modified crankshafts are listed in Information The modified crankshafts may be fitted as replacements to engines prior to these engine numbers For inspection purposes journal sizes on crankshafts fitted to early engines are listed as Type A whilst those fitted to later engines...

Page 221: ...ENGINE 1 f 1 j 1 U 1 u 1 I t In i s n J 1 1 i I I W ir T 1 r 1 2 3 4 5 A C C B A 8 4 OVERHAUL ...

Page 222: ...EN BLUE BLUE Colour code on edge of bearing Thickness progression GREEN Thin BLUE Intermediate RED Thick CAUTION If two bearing colours are to be used thicker bearing must be fitted to bearing ladder j When original crankshaft is to be refitted bearing shells must be as selected from table DO NOT FIT UNDERSIZE BEARINGS Main bearings type table 1 2 3 4 5 Block Plain Grooved Grooved Grooved Plain La...

Page 223: ... sfilection table mm 1 8 litre Big end journal tolerance Grade A 48 000 to 48 007 mm Grade B 47 993 to 48 000 mm Grade C 47 986 to 47 993 mm Clearance in bearings 0 021 to 0 049 mm Maximum out of round 0 010 mm Big end connecting rod end float 0 10 to 0 25 mm 3 Select the appropriate big end bearing shells from the table 4 Replace crankshaft if outside tolerance Big end bore Crankshaft big end jou...

Page 224: ...dder using suitable solvent 6 2M1780 6 Apply a continuous bead of sealant Part Number GUG 705963GM to paths shown on cylinder block then spread to an even film using a roller CAUTION To avoid contamination l assembly should be completed immediately after application of sealant a 2 Fit selected main bearing shells into cylinder block and bearing ladder as indicated in the table 3 Fit thrust washers...

Page 225: ...kshaft will prove difficult to rotate once big end bolts are tightened 11 Using feeler gauges check that end float of each big end bearing connecting rod is between 0 10 to 0 25 mm 12M1781 12 Apply continuous beads of sealant Part Number QUG 705963GM to paths on oil rail as shown then spread to an even film using a roller CAUTION To avoid contamination j assembly should be completed immediately af...

Page 226: ...3 new M6 or M8 x 35 Patchlok bolts at positions 4 8 and 12 to 5 Nm 22 Progressively tighten sump bolts in sequence shown to M6 M8 bolts 10Nm 23 Fit anti beaming bracket where fitted tighten bolt to 45 Nm ENGINE Vcxrq Alloy sump 24 Clean sealing surface on sump flange using suitable solvent 12M1782 25 Apply a 2 mm wide x 0 25 mm thick continuous bead of sealant Part Number GUG 705963GM to sump flan...

Page 227: ...s into holes shown tighten to 4 Nm 29 Fit 10 bolts into remaining holes lightly tighten all bolts CAUTION Ensure 2 M8 x 60 bolts are in j original fitted positions 30 Remove alignment pins 18G 1744 fit and lightly tighten remaining 2 bolts 31 Using a straight edge check that machined face of sump flange is level with rear face of cylinder block Check in 3 positions and if necessary tap sump gently...

Page 228: ...w gasket dry and fit dipstick tube tighten bolts to 10 Nm A NOTE Ensure bolts securing dipstick tube to bearing ladder are flanged head and do not exceed 12 mm in length 44 Support engine and using a socket and suitable torque gauge on crankshaft pulley bolt check that crankshaft can be rotated in a clockwise direction without undue binding rotational torque should not exceed 31 Nm 45 Fit spark pl...

Page 229: ...are that big ends do not contact surface of cylinder liners 7 Refit caps on to connecting rods lightly tighten dowel bolts CAUTION Removal of pistons will j necessitate removal and re sealing of cylinder liners Piston rings checking 1 Using an expander remove and discard old piston rings Use squared off end of broken pistonringand 2 3 clean ring grooves Check newringto groove clearance 12M1785 KB ...

Page 230: ... mm ENGINE Pistons inspection Check pistons for distortion and cracks Measure and record piston diameter at right angle to gudgeon pin and 8 mm from bottom of skirt Check piston diameter with figures given Measure and record piston diameter in line with gudgeon pin hole and 8 mm from bottom of skirt Check piston ovality with figures given Repeat above procedures for remaining pistons K8 and K 1 6 ...

Page 231: ...linder liner bore K8 and K16 1 1 and1 4 0 015 to 0 045 mm K16 1 6and 1 8 0 01 to 0 04 mm Piston rings refit CAUTION Ensure that piston rings are fitted to piston for the cylinder bore in which they were checked 1 Fit oil control spring 2 With TOP or identification markings to top of piston use an expander to fit piston rings in sequence oil control 2nd and top compression 12M1811 3 Ensureringsare ...

Page 232: ...iner CAUTION Cylinder liners with excessively j glazed worn scratched or scored bores must be replaced do not attempt to h o n e or remove glazing f r o m bore A B Cylinder liner bore grade V Z Cylinder liner step height A NOTE Cylinder liners fitted to later 1 8 engines have their step heights graded on production The step heights V or Z together with the liner part number and colour code are mar...

Page 233: ...ed 12M1787 CAUTION If original cylinder liners are to j be refitted use a felt tipped pen to make suitable alignment marks between liner and cylinder block Do not etch or stamp liners 4 Using hand pressure push cylinder liners out towards cylinder head face ol cylinder block remove liners 12M1788 A CAUTION Keep cylinder liners in their fitted order 5 Apply a 2 0 mm thick continuous bead of sealant...

Page 234: ... are correctly spaced 4 Fit selected bearing shells into big end bearing caps and connecting rods 5 Fit ring clamp 18G 55A to each piston in turn and with FRONT mark on piston to engine front push piston into bore until flush with top face of cylinder liner Remove ring clamp CAUTION If original pistons are to be j fitted ensure that each piston is inserted in its correct cylinder liner Do not push...

Page 235: ...gines Service limit Camshaft bearing clearance K16 W C engines Inlet 25 mm diameter journals Service limit Inlet 40 mm diameter journals Service limit Exhaust Service limit Tappets Tappet outside diameter Cylinder head Cylinder head maximum warp Cylinder head height New Reface limit 0 28 to 0 36 mm 0 05 to 0 13 mm 0 02 to 0 06 mm 38 9 mm 88 C 85 to 91 C 100 C 0 06 to 0 19 mm 0 3 mm 0 03 to 0 15 0 ...

Page 236: ...alve guides Inside diameter Valve stem to guide clearance Inlet Service limit Exhaust Service limit Valve stem fitted height New Service limit 6 960 to 6 975 mm 6 952 to 6 967 mm 7 000 to 7 025 mm 0 025 to 0 065 mm 0 07 mm 0 033 to 0 073 mm 0 11 mm 38 95 to 40 81 mm 41 06 mm K16 engines Valve stem diameter Inlet Exhaust Valve guides Inside diameter Valve stem to guide clearance Inlet Service limit...

Page 237: ...urnal tolerance Type B crankshaft Grade 1 48 000 to 48 007 mm Grade 2 47 993 to 48 000 mm Grade 3 47 986 to 47 993 mm Clearance in bearings 0 013 to 0 043 mm Maximum out of round 0 010 mm Big end journal tolerance 1 1 1 4 and 1 6 litre Grade A 43 000 to 43 007 mm Grade B 42 993 to 43 000 mm Grade C 42 986 to 42 993 mm Clearance in bearings 0 021 to 0 049 mm Maximum out of round 0 010 mm Big end co...

Page 238: ...ntrol rails 0 15 to 0 40 mm K16 1 6 and 1 8 Top compression ring 0 20 to 0 35 mm 2nd compression ring 0 28 to 0 48 mm Oil control rails 0 15 to 0 40 mm Piston diameter K8 and K16 1 1 and 1 4 Grade A 74 940 to 74 955 mm Grade B 74 956 to 74 970 mm Clearance in bore 0 015 to 0 045 mm Maximum ovality 0 3 mm K16 1 6 and 1 8 Grade A 79 975 to 79 990 mm Grade B 79 991 to 80 005 mm Clearance in bore 0 01...

Page 239: ...tube bolts 10 Nm Flywheel 80 Nm Fuel pump blanking plate nuts K8 25 Nm ht lead brackets not plug top coil ignition 10 Nm ht lead cover screws 5 Nm Hydraulic control unit bolts K16 VVC engines 25 Nm Hydraulic control unit piston to rack screw 9 Nm Hydraulic control unit oil temperature transmitter 15 Nm Hydraulic control unit spool valve nut K16 VVC engines 26 Nm Hydraulic control unit spool valve ...

Page 240: ...t housing bolts Plastic housing 8 Nm Thermostat housing to cylinder block bolt 10 Nm Timing belt tensioner bolt Automatic tensioner 25 Nm Timing belt tensioner pulley Allen screw Manual tensioner 45 Nm Timing belt tensioner pulley backplate screw Manual tensioner 10 Nm Timing belt tensioner pillar bolt 25 Nm Timing belt lower cover screws 9 Nm Timing belt rear cover screws 9 Nm Timing belt upper f...

Page 241: ...t Front Oil Seal Replacer K16 VVC Housing Oil Seal Replacer Flywheel Locking Tool Flywheel Fitted With Reluctor Ring Cylinder Liner Retainer Clamps Sump Alignment Pins 2 off Camshaft Front And Rear Oil Seal Replacer Camshaft Clamp K16 VVC Engines Timing Plate Front Inlet Camshaft K16 VVC Engines Timing Plate Rear Inlet Camshaft K16 VVC Engines Camshaft Oil Seal Protection Sleeve Valve Guide Reamer...

Page 242: ...EMN 6 9 Crankshaft Position Sensor EMN 7 10 Engine Coolant Temperature ECT Sensor EMN 8 11 Intake Air Temperature IAT Sensor EMN 9 12 Throttle Position TP Sensor EMN 10 13 Idle Air Control IAC Valve EMN 11 14 Oxygen O2 Sensor EMN 12 15 Camshaft Position Sensor WC only EMN 13 16 WC Mechanism Control Solenoids WC only EMN 14 17 Oil Temperature Sensor WC only EMN 15 18 Fuel System EMN 16 19 Ignition ...

Page 243: ...Lotus Service Notes Section EMN Page 2 2000 0 1 ...

Page 244: ...l ratio is calculated by the ECM using a three dimensional map to provide a basic fuelling specification under various operating conditions In order to refine the fuel delivery and cater for special conditions various types of compensation are provided Cranking enrichment During cranking when engine speed is below about 400 rpm the injection pulse width is increased dependent on coolant temperatur...

Page 245: ...eck instruction booklet EMN 2 LOTUS CHECK SCANNER TOOL In order to provide for communication with the engine management system electronic control module a hand held electronic scanner tool Lotus Check part number T000T1346 may be plugged into a special 16 terminal harness connector socket known as a Data Link Connector DLC located in the rear luggage com partment Cars without bootbox pre Sept 98 B...

Page 246: ...rned on the ECM will reinstate the sensor input but will record the fault in memory Dependent on the nature of the fault this may or may not have been noticed by the driver At each maintenance service the Lotus Check tool should be connected and the Pre Test selected from the main menu to check whether any faults have been detected since the last Pre Test This test takes only a few minutes during ...

Page 247: ...rature The test should be used any time that a driveability concern is reported or if the Pre Test does not identify the problem Components tested in this routine include Coolant temperature sensor Fuel injectors Fuel pump Oxygen sensor heater relay Purge valve solenoid VCC control solenoids note that it is not normally possible to hear these solenoids operate Throttle position sensor Cooling fan ...

Page 248: ...ed signal from the security module before the unit becomes operative The engine ECM is an adaptive unit which learns the optimum setting of the idle air control valve and the fuelling offset required to achieve the correct exhaust oxygen content for a particular engine relative to its wear and performance characteristics This feature speeds the response of the system and minimises the time spent a...

Page 249: ...rent to the ECM when the ignition is switched on When the ignition is switched off the ECM will keep the main relay energised for a short period whilst the IAC valve is driven to its power down position ready for the next engine start Fuel Pump Relay Energised by the ECM for a 3 second period each time the ignition is switched on Continuously fed during engine cranking and while the engine is runn...

Page 250: ...perture Faults with the MAP sensor require that the ECM be replaced When using the Lotus Check tool an atmospheric pressure of approximately 100 KPa should be dis played with the engine stopped and a lower value between 25 40 KPa during idle Very high values may indicate a faulty sensor or a blocked or leaking connecting hose Moderately raised values indicate a possible engine fault On W C engined...

Page 251: ... follows relative to no 1 cylinder Standard TDC 50 BTDC 180 BTDC 240 BTDC WC 110 BTDC 150 BTDC 300 BTDC 330 BTDC Note that on standard engines using grouped injection 1 with 4 2 with 3 it is not necessary to determine which cylinders are on the firing and which on the exhaust stroke On the W C engine using fully sequential injection an additional signal from the camshaft position sensor is require...

Page 252: ...rature the resistance will be approximately 300 400 ohms This data is also used to control the radiator fan which is switched on by the ECM at a rising coolant temperature of 102 C and switched off on falling temperature at 96 C If the ECM receives a signal voltage outside of the acceptable range a default setting equating to 60 C will be substituted and the cooling fan energised To replace the se...

Page 253: ...r consumption of the engine and adjust the injector pulse width accordingly for correct fuelling Low air temperature results in denser air requiring more fuel High air temperatures are also used by the ECM to retard the ignition timing and avoid knock Inlet Air Temperature IAT sensor shown Inlet manifold To replace the sensor unplug the electrical connector and unscrew the sensor from the manifold...

Page 254: ... the resistance will be approximately 300 400 ohms This data is also used to control the radiator fan which is switched on by the ECM at a rising coolant temperature of 102 C and switched off on falling temperature at 96 C If the ECM receives a signal voltage outside of the acceptable range a default setting equating to 60 C will be substituted and the cooling fan energised To replace the sensor d...

Page 255: ... is able to determine the air consumption of the engine and adjust the injector pulse width accordingly for correct fuelling Low air temperature results in denser air requiring more fuel High air temperatures are also used by the ECM to retard the ignition timing and avoid knock Inlet Air Temperature IAT sensor shown Inlet manifold To replace the sensor unplug the electrical connector and unscrew ...

Page 256: ... manifold depression and keep emissions low Fuel is progressively reinstated as the throttle position sensor is opened When using the Lotus Check scanner tool Throttle Bits shows the raw signal received by the ECM from the TP sensor and will range from 0 closed to 255 fully open The full range of values will not be seen in practice Throttle Switch indicates whether the ECM detects an open or close...

Page 257: ...ures that the idle ari control valve is able to supply varying amounts of by pass air to compensate for all loads and temperature conditions If outside of this range there is likely to be a mechanical fault such as an intake manifold air leak Using the Lotus Check scanner IDLE HOTDBPOS indicates the number of IAC valve steps from fully closed 0 which the ECM has learned as the position required to...

Page 258: ...ce the engine is fully warm and during most idle and driving conditions this voltage will switch rapidly between 0 7 V 1 0 V The FEEDBACK display indicates the current feedback fuelling correction This is shown as a percentage of the mapped open loop value This percentage is continuously updated by the ECM whenever the conditions for closed loop fuelling are present At other times the feedback val...

Page 259: ...tect the engine from potential damage If sensor failure occurs whilst the engine is running the engine will continue to run in sequential fuelling mode until ignition switch off If the ECM detects any faults with cam period measurement during start up and initial running the ECM will try and drive dependent on the cause of the fault the mechanism to minimum cam period Engine speed will be limited ...

Page 260: ...r To replace the solenoids Unplug the harness connectors Release the adjacent breather pipes and harnesses to provide access to the sleeve nut Remove the nut and slide the two solenoids off the spool valve shaft taking care not to misplace the O rings and spacer When refitting lubricate all O rings and spool valve shaft with engine oil and note that although the two solenoids are identical the cor...

Page 261: ...rature is used by the ECM to determine how quickly the W C mechanism will respond to cam period change com mands To replace the sensor unplug the electrical connector brown and unscrew from the hydraulic control unit Fit a new seal onto the sensor before inserting and tightening to 15 Nm OH temperature sensor O Page 18 2000 01 ...

Page 262: ...nnect the battery Use a shop towel to absorb the small amount of pressurised fuel remaining as a fuel feed pipe connection is released and dispose of safely The modular fuel pump sender assembly uses an electric motor to power a three stage impeller type pump system submerged within the tank In order to avoid fuel starvation from surge effects caused by vehicle acceleration and cornering forces th...

Page 263: ...y If the engine stalls the ECM will switch off the pump lifter about 10 seconds A safety inertia switch is mounted ahead of the ECM and controls the supply to the fuel pump relay Vehicle impact will trip the switch and isolate the fuel pump Reset by pressing the button on top of the switch Inertia switch The single fuel rail is used to link the four port injectors to provide a balanced fuel supply...

Page 264: ... faulty If this makes little or no difference the fuel pump may be restricted or faulty If above specification the regulator valve may be faulty v With the engine still idling re connect the vacuum hose to the regulator valve The pressure should drop to approximately 2 2 bar If the pressure does not drop check the hose for kinking or blockage or replace the regulator valve vi Switch off the igniti...

Page 265: ...lar as shown Fuel feed hose push fit connector orange Convolute sleeving Fuel return hose push fit connector green Tie wrap fitted around release collar Fuel Injectors The four fuel injectors are fitted between the pressurised fuel rail and the inlet manifold Each injector comprises a solenoid operated needle valve and a specially designed nozzle to ensure good fuel atomisation The ECM energises t...

Page 266: ...Release the fuel return hose from the right hand end of the fuel rail and plug the connections 5 Remove the two screws securing the fuel inlet pipe to the left hand end of the rail and withdraw Discard the O ring and plug the connections 6 Unplug the injector harness connector and release from its retaining bracket 7 Remove the two bolts securing the fuel rail to the inlet manifold and carefully w...

Page 267: ... rear end of the inlet camshaft and low tension control circuitry within the ECM The ECM controls ignition timing based on inputs from the following sensors Crankshaft position sensor supplies engine speed and crankshaft position information Manifold absolute pressure sensor supplies engine load information Engine coolant temperature sensor allows timing variations for optimum cold driveability an...

Page 268: ...onnected in series with the supply and the ECM and an isolated secondary winding connected in series with two spark plugs It is important to note that there is no connection between the primary and secondary windings The coils are triggered by the ECM which switches off the primary voltage and induces a high tension current to produce a spark in the spark plug connected to each end of the secondar...

Page 269: ...tion FH TRANSMISSION SECTION FH M111 ELISE Sub Section Page Introduction FH 1 2 Gearchange Mechanism FH 2 2 Lubrication FH 3 6 Driveshafts FH 4 6 m Transmission Replacement FH 5 10 Transmission Overhaul Special Tools FH 6 11 ...

Page 270: ...ed to connect the gearchange lever with the transmission one cable shift to transmit the fore aft movement of the lever and a second crossgate for the sideways movement The steel gearchange lever incoporates an integral pivot ball which pivots in a two piece nylon socket in an alloy housing The housing is mounted on a fabricated steel bracket which incorporates abutments for the two cables and is ...

Page 271: ...nd abutment bracket with crossgage adjustment catered for by an adjustable length tie rod between transmission end bellcrank lever and selector shaft With the gearchange mechanism assembled and the transmission in neutral 1 Fore aft position Viewed from the side the lower part of the gear lever before the rearward bend should be vertical or leaning very slightly to the rear If necessary slacken th...

Page 272: ...to limit the gear lever crossgate move ment to the right 5th and reverse plane If any adjustment to the crossgate cable is made the stop bolt adjustment should be checked For access to the lever mechanism the gear lever knob and shroud must first be removed unscrew the knob remove the screw each side of the shroud and lift the shroud over the lever The nominal stop bolt setting of 12 mm should be ...

Page 273: ...pivot into the gear lever housing and retain with the E clip Fit the crossgate spigot into the bellcrank lever and locate the gear lever housing onto the mounting bracket Fit and tighten the three gear lever housing screws and snap the select cable socket onto the bottom of the gear lever Check gear linkage operation and adjustments before fitting the pivot ball dust shield over the lever and refi...

Page 274: ... tify the fault A filler level plug is provided on the left hand side of the the final drive housing and with the car parked on a level surface the oil level should be up to the level of this hole A drain plug in the underside of the casing square socket plug permits the oil to be drained prior to transmission removal or re pair Dry fill capacity 2 4 litres Refill 2 1 litres Level filler plug Drai...

Page 275: ...96 and fitted from transmission number C6BP 2009713 The new B type seals incorporate a steel insert to protect the seal lips and have a location flange on their outside diameter When replacing a seal compatibility with the driveshaft see below must be maintained Although the transmission casing was revised for the B type seal to include a machined face for the seal flange to butt against if neces ...

Page 276: ...d may entail replacement of the joint The components of the inboard plunging joint are held in position for transit purposes only by a collar within the boot which will be overidden if excessive axial force is used Apply pressure only to the tulip or outer body of the joint Withdraw the inboard C V joint from the transmission taking great care not to damage the output seal and fit blanking plug T0...

Page 277: ...that any interchang ing or re orientation of parts is likely to result in premature failure If the grease in the joint is contaminated with dirt or water it is likely that the joint is damaged and should be replaced If the grease is not contaminated the joint should be degreased by soaking in a suitable solvent NOT petrol and then carefully inspected On the outboard ball type joint tilt the inner ...

Page 278: ...ay 2 Release the RH rear suspension toe control link from the hub carrier and release the top ball joint plinth from the hub carrier taking note of the camber adjustment shimplates in order to allow withdrawal of the driveshaft from the transmission 3 Release both driveshaft inboard C V joints from the transmission using special wedge tool T000T1276 or by applying a shock pull to the C V joint bod...

Page 279: ...wing part numbers Transmission Special Tools Description Lotus Part No Driveshaft Removal Wedge T000T1276 Adaptor Plate bearing puller T000T1291 Driver Handle bearing dolly T 0 0 0 T 1 2 9 2 Replacer Dolly input shaft oil seal T 0 0 0 T 1 2 9 3 Slide Hammer output shaft bearing remover T000T1294 Adaptor output shaft bearing remover T000T1295 Driver Handle bearing dolly T 0 0 0 T 1 2 9 6 Replacer D...

Page 280: ...ellingsbakrevisiehandboek PGl Boite de vitesses manuelle Manuel de revision PGl Schaltgetriebe Uberholungsanleitung PGl Cambio meccanico Manuale di revisione PGl Caja de cambios manual Manual de revisidn PGl Caixa de velocidades manual Manual de revisao RCL 0124 ...

Page 281: ... models Rover 218 418 Diesel New Rover 200 Diesel New Rover 218 New Rover 400 Diesel Rover 220 Rover420 Rover 600 Diesel Rover 600 Ti Rover 820 Rover 800 KV6 MG F Publication Part No RCL 0124 ENG 2nd edition Published by Rover Technical Communication 1997 ROVER GROUP LIMITED ...

Page 282: ...e to components MOTS Gives helpful information The dimensions quoted are to design engineering specification with Service limits where applicable REPAIRS AND REPLACEMENTS When replacement parts are required it is essential that only Rover recommended parts are used Attention is particularly drawn to the following points concerning repairs and the fitting of replacement parts and accessories Safety...

Page 283: ... Manual does not constitute an offer for sale of any particular component or vehicle Rover Dealers are not agents of Rover and have no authority to bind the manufacturer by any expressed or implied undertaking or representation Gearbox identification This overhaul manual is applicable to PG1 gearboxes having the following Serial No prefixes C4BP R4A0 C4BS R4DT C6BN S4DTU C6BP S4EM C6BS S4FTU S6BSU...

Page 284: ...ck Assembly 12 Differential Assembly 12 INSPECTING COMPONENTS 13 Input and Output Shaft Assemblies 13 Reverse Idler Shaft and Gear 14 Synchro Assemblies 14 Selector Shafts and Forks 15 Interlock Assembly 16 Differential Assembly 17 Differential Housing 17 COMPONENT ASSEMBLING 19 Differential 19 Synchro Assemblies 19 Selector Shafts 20 Reverse Idler Gear and Shaft 20 Input Shaft 20 Output Shaft 22 ...

Page 285: ...MANUAL GEARBOX This page is intentionally left blank DESCRIPTION AND OPERATION 1 ...

Page 286: ...SIUAL GEARBOX 37M1297 DESCRIPTION AND OPERATION REVISED ...

Page 287: ...t 75 Selective snap rings input shaft end thrust 76 Belleville washer input shaft end thrust 77 Oil guide plate 78 Gearbox casing 79 Reverse idler shaft bolt and washer 80 Breather pipe 81 Breather pipe bracket 82 Oil seal differential 83 Filler level plug 84 Drain plug 85 Access plug output shaft bearing circlip 86 Reverse light switch 87 Interlock assembly early gearboxes 88 Gearshift holder 89 ...

Page 288: ...erse idler gear 6 Breather pipe and bracket 7 Differential housing 8 Access plug output shaft bearing circlip 9 Output shaft assembly 10 Shift arm assembly and interlock 11 Selective shim 12 Final drive assembly 13 Speedometer drive pinion housing 14 Selector shaft 15 Oil drain plug 16 Oil filler level plug 4 DESCRIPTION AND OPERATION ...

Page 289: ...cal gears is controlled by a combination of thrust washers and needle roller bearings located at each end of and between the two gears Type B The assembly comprises a final drive gear bolted to the differential casing two helical side gears splined to the drive shafts and four pairs of element gear assemblies arranged at ninety degree intervals within the differential casing and running parallel t...

Page 290: ... Torsen differential Type A Serial number prefixes K4BX and K7BSUT 1 Helical side gear 2 Element gear assembly worm and spur gears 3 Journal pin 4 Thrust washer and spacing washer 5 Two thrust washers and needle roller bearing 6 DESCRIPTION AND OPERATION ...

Page 291: ...d between the side gears whilst on Type B differentials a combination of thrust washers and friction washers is used When both front wheel speeds are equal then the frictional loads imposed by the element gears on the side gears are also equal However when the drive resistance on a road wheel is reduced through loss of traction then a torque imbalance is created less torque being required to turn ...

Page 292: ...a lock plate The inner face of the lock plate is angled approximately at 45 with two machined flanges either side of the lock plate which are positioned in machined grooves in the guide lugs A return spring which biases the lock plate against the stop surface extends along the step at the front of the lock plate with the two free ends of the spring held in position by two Taptfte screws either sid...

Page 293: ...nt continued upward movement of the 5th reverse shift piece 1 causes the lock plate 3 to move the 3rd 4th selector and synchro sleeve 5 towards 4th gear The movement of the 3rd 4th synchro sleeve 5 is sufficient to restrain the input shaft 6 thus permitting smooth engagement of reverse gear To prevent any further movement of the 3rd 4th synchro sleeve 5 and engagement of 4th gear the spring on the...

Page 294: ...nze and are gold in colour Do not interchange selector forks or shafts between type A and B assemblies 4 Slide 5th reverse gear selector off 5th reverse selector shaft 5 Slide 3rd 4th and 5th selector forks off 5th reverse selector shaft 1 Identify each selector fork and its fitted position to the relevant selector shaft Slide 1st 2nd gear selector fork off 1st 2nd selector shaft 2 Slide 1st 2nd s...

Page 295: ...ted under two Taptite screws 5 which are positioned either side of the 5th reverse selector Interlock Assembly 37M1292 37M1165 NOTE A modified interlock assembly having 2 springs has been introduced this assembly may be fitted as a replacement to early gearboxes 1 Withdraw shift shaft from gearshift holder and arm guide 2 Release lug on arm guide from slot in interlock 3 Slide gearshift holder off...

Page 296: ...fitted check clutch release shaft bushes for damage or wear and that shaft is free to turn replace if necessary using the following procedure Remove 3 Remove speedometer drive gear using a suitable three legged puller and thrust button Standard differential 4 Check pinion shaft for wear 5 Check speedometer drive gear teeth for wear or damage replace as necessary 2 Outer bush Using a hacksaw blade ...

Page 297: ...uter bush into differential housing A CAUTION Ensure end of tool 18G 1723 2 is located in inner bush 6 Gearboxes fitted with output shaft bearing retainer plate Remove all traces of Patchlok compound from output shaft bearing retainer plate bolt holes using an M6 tap CAUTION Ensure bolt holes are thoroughly cleaned 18 OVERHAUL REVISED 12 97 ...

Page 298: ...the gearbox can be assembled it will not be possible to select 5th gear COMPONENT ASSEMBLING Differential 1 Assemble planet gears and original thrust washers 2 Fit sun gears and original thrust washers if fitted 3 Rotate gears and thrust washers to align drillings in carrier CAUTION Do not fit roll pin or final drive gear at this stage Torsen differential 4 Position speedometer drive gear on carri...

Page 299: ...ift holder to interlock fit shaft Reverse Idler Gear and Shaft 1 Fit a new thrust washer 2 Smear needle bearing rollers with petroleum jelly and fit in idler gear 3 Fit reverse idler gear to shaft A NOTE Boss on gear must face towards thrust washer Input Shaft NOTE Smear needle bearing rollers with petroleum jj Hy prior to assembly 1 Fit needle bearing rollers in third gear 2 Fit 3rd gear on shaft...

Page 300: ...ft 1 Position differential assembly with bearings located in V blocks 2 Fit both inboard drive shaft joints to align gears 3 Assemble a DTI gauge with stylus of gauge contacting one of the planet gears zero the gauge 4 Measure and record planet gear backlash 5 Repeat procedure for other planet gear 6 Compare backlash figures obtained with the following Planet gear backlash 0 05 to 0 15 mm 7 If bac...

Page 301: ... case to seat circlip 5 Lightly drive differential into differential housing to settle bearing 6 Using feeler gauges measure and record clearance between circlip and bearing outer face Correct clearance 0 15 mm maximum 7 If clearance is not as specified select the appropriate circlip from the range available NOTE Circlips are available from 2 50 to 3 00 mm thick in increments of 0 10 mm 8 Remove o...

Page 302: ...ng on application output shaft bearing may have oil holes drilled m bearing cage these holes must face towards output shaft when fitting bearing Bearings without the oil hole may be fttted Hher way round 5 Fit a new input shaft oil seal in differential housing using tools 18G 1354 and 18G 1354 4 6 Fit input shaft bearing into differential housing using tools 18G 1354 and 18G 1354 6 REVISED 12 97 O...

Page 303: ...lt to 22 Nm Position differential assembly into housing 18G 1269A 37M0178 14 15 A Fit seal protector tool 18G 1269A to input shaft or apply masking tape to splines to protect oil seal Place input and output shafts together and fit assembly in differential housing NOTE Position housing so that when fitted end ol input shaft is clear of bench 16 Remove tool 18G 1269A 17 Ensure output shaft nut is st...

Page 304: ...ss plug fit and tighten plug using tool 18G 1472 Fit reverse light switch and new washer tighten to 25 Nm Fit speedometer drive pinion and housing use a new O ring fit retaining plate fit and tighten bolt to 5 Nm Fit new clutch release shaft oil seal Fit clutch release shaft and fork Fit and tighten bolt to 29 Nm 37M1146A 25 Fit new differential oil seals in gear case NOTE Type A oiS seal use 18G1...

Page 305: ...ice Notes Section EMN WHEELS TYRES SECTION GF M111 ELISE Sub Section General Description GF 1 2 Winter Tyres Snow Chains GF 2 4 Emergency Punctured Tyre Inflator GF 3 4 Security Wheelnuts GF 4 5 2000 7 01 Page 1 ...

Page 306: ...d depth limits are approached The cold tyre pressures should be checked every week or every 1 000 miles 1 700 km whichever is the sooner and corrections made as necessary Under inflation will cause excessive wear rapid deterioration of the tyre sidewalls and heavy steering whereas overinflation results in a hard ride and increased susceptibility to tyre damage Both conditions will cause a degradat...

Page 307: ...ed on production at VIN V1700 approx Italian and U K variations of rear tyre should not be mixed on the same axle Italian built rear tyres are available under part number A111G6007H but will be superceded by the new U K built version U K built Lotus approved rear tyres are available under part number A111G6022H The DOT code is moulded on the outside wall with only the last number group relevant to...

Page 308: ...on pressed a mixture of liquid latex and propellant is injected into the tyre such that the solidifying latex is forced into the puncture site at the same time as the tyre is inflated effecting a temporary repair and enabling the car to be driven at moderate speed to the nearest tyre depot WARNING Use of the aerosol does not constitute a permanent repair but is designed to allow the car to be driv...

Page 309: ...tor canister GF 4 SECURITY WHEELNUTS On cars so equipped each of the four road wheels is fitted with one security keyed wheel nut in order to deter theft and vandalism The special splined security nut requires a matching key coded socket before it may be removed using a standard 19mm wheelbrace For aesthetic purposes the coded nut is capped by a metal cover which may be removed using an extractor ...

Page 310: ...E Sub Section Page General Description HE 1 2 Steering Wheel HE 2 2 Upper Column Assembly HE 3 4 Intermediate Column HE 4 7 Front Wheel Alignment Rack Gaiters HE 5 8 Rack Pinion Assembly Removal Replacement HE 6 9 Adjustment of Rack Bar Thrust Pad HE 7 10 Page 1 ...

Page 311: ...ges allow for telescoping of the column in a frontal collision The steering rack assembly which provides 2 4 turns from lock to lock at a 15 8 1 ratio is rigidly mounted inside a chassis transverse extrusion behind the top wishbone rear pivots HE 2 STEERING WHEEL The alloy three spoke steering wheel has a leather trimmed rim and moulded rubber covered spokes and is secured to the column via a 36 s...

Page 312: ...er the telescoping mechanism of the outer column may be overridden necessitating column replacement 5 If necessary unclip the slip ring from the steering wheel boss and withdraw with the horn lead Withdraw the column bearing preload spring 6 To refit the steering wheel reverse the above procedure with the following notes Clip the horn slip ring to the steering wheel boss with the turn indicator ca...

Page 313: ...sitions 3 Secure the steering wheel before road testing the car and marking the actual straight ahead position of the steering wheel which should deviate from the ideal position by less than 5 Final alignment is achieved by asymmetric adjustment of the track rods retaining the overall toe out setting HE 3 UPPER COLUMN ASSEMBLY Break out insert Column support bracket Turn flasher switch Alarm modul...

Page 314: ...y insert bolted through to an extruded alloy plinth fixed to the scuttle beam In the event of an extreme axial load being applied to the column via the steering wheel as may occur during a vehicle frontal collision the plastic retaining pins in the column flange inserts will shear and allow the upper part of the column to break free of the upper fixings and telescope forwards reducing the potentia...

Page 315: ...lts 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 Alloy break out insert To Remove Upper Steering Column Assembly 1 Disconnect the battery and remove the column shrouds see sub section HE 2 2 Disconnect the column lever switches or release the retaining pawls and slide the switches o...

Page 316: ...ng the column upper mounting flanges captive nuts Remove the Lucas module and bracket and release the single lower column fixing Withdraw the column assembly from the scuttle and off the inter mediate steering column Refit the column in reverse order to removal with the following notes The groove for the pinch bolt al lows assembly of the universal joint to the intermediate column in only one orie...

Page 317: ...st remain equal adjust each track rod by a similar amount Hold the track rod end using the flats provided and slacken the locknut Repeat for the opposite side Turn each track rod a similar amount As a guide turning both track rods by one quarter of a turn will alter overall toe out by approx 2 0 mm When adjustment is correct hold each track rod end and tighten the locknuts to 80 82 Nm 58 60 Ibf ft...

Page 318: ...tion of the housing Note that the only approved repairs or adjustments to the steering rack assembly are the replace ment of the track rod ends and rack housing gaiters and the adjustment of the rack pressure pad Steering rack assembly Steel reinforcement channel bonded Height setting plate M10 fixing bolt M8 fixing bolt Pop rivet Chassis crossmember HtmI To Remove Replace Steering Assembly 1 Remo...

Page 319: ...ng arms and tighten the nuts to 30 Nm 9 Check and adjust the front wheel alignment as detailed in sub section CG 2 HE 7 ADJUSTMENT OF RACK BAR THRUST PAD A thrust pad backed by a pair of belleville washers is used to control the preload between the rack bar teeth and the pinion gear and is adjustable via a theaded backstop plug The correct preload allows the horizontally mounted rack bar column di...

Page 320: ...1 Sub Section Paqe General Description JH 1 3 Brake Fluid Check Change JH 2 3 Front Brake Pad Replacement JH 3 4 Rear Brake Pad Replacement JH 4 5 Parking Brake Mechanism JH 5 6 Brake Discs JH 6 9 Master Cylinder JH 7 10 Pedal Box JH 8 13 Caliper Overhaul JH 9 15 Page 18 ...

Page 321: ...Lotus Service Notes Section JH 1 m o s a a U Q t s Page 2 ...

Page 322: ... for any potential affect on brake performance due to temperature change The braking system is designed to enhance brake performance during high speed driving with good fade and pad wear characteristics and have a higher friction level when heated to normal working temperature than when cold Required pedal effort will reduce as cold brakes become heated to normal working temperature After fitting ...

Page 323: ...E PAD REPLACEMENT Pad thickness may be checked with the wheel removed without disturbing the caliper Alloy discs Iron discs Standard pad thickness excluding backplate 10 0 mm 9 0 mm Minimum pad thickness excluding backplate 2 5 mm 2 5 mm If the thickness of any pad is below the specified minimum the axle set of pads should be renewed Note that different brake pads are used for aluminium and iron d...

Page 324: ...fficiency will be achieved if for the first few hundred miles needless heavy braking is avoided and the brake pads are allowed to bed in fully before being used to their full potential JH 4 REAR BRAKE PAD REPLACEMENT Pad thickness may be checked after removing the road wheel without disturbing the caliper Alloy discs Iron discs Standard pad thickness excluding backplate 7 8 mm 6 5 mm Minimum pad t...

Page 325: ...spring eyes into alignment whilst the pad retaining pin is inserted through the caliper from the outside Ensure that the pin passes through both eyes of the anti rattle spring and both brake pads and that the pin is fully installed with the snap ring seated in the outboard side of the caliper Anti rattle spr 8 Refit the roadwheels and press the brake pedal several times to set the brake pad positi...

Page 326: ...his way the mechanical mechanism is adjusted automatically to compensate for pad wear Needle roller thrustbearing spring bolt in ramps ni26i For the auto adjustment system to function correctly it is essential that each caliper parking brake lever is allowed to return fully when the brake is released and is not prevented from doing so by maladjustment of the parking brake cable To check that the c...

Page 327: ...s sandwiched into a mounting bracket by two flat head bolts securing the ratchet plate The mounting bracket in conjunction with the gearchange lever bracket is not drive handed but is offset via alternative fixing holes in the chassis towards the passenger side The ratchet pawl operates a micro switch to light the brakes tell tale lamp in the instrument panel whenever the ignition is switched on a...

Page 328: ...dusty or unmade road environments and will reduce braking performance No skimming or re surfacing of the brake discs is permitted If the disc becomes badly scored or is out of specification in any way it should be renewed NOTE Ensure that there is no discernible free play in the wheel bearings before attempting to measure brake disc run out Brake disc thickness New 26 0 mm 1 02 in Service minimum ...

Page 329: ...t plate within the pedal box To Replace Seals 1 Thoroughly clean the exterior of the master cylinder assembly before commencing in a clean environ ment any dismantling operation 2 Carefully withdraw the fluid reservoir spigots from the master cylinder grommets 3 Remove the pushrod boot and the front piston stop bolt and washer 4 Using a rounded end mandrel press the rear piston into the cylinder s...

Page 330: ...piston with the lip facing forwards Fit the support ring onto the piston nose to retain the seal and form a seat for the cylinder front spring Fit a pair of secondary seals 03 3301 1934 1 into the two grooves at the rear end of the piston with the lip of the front seal facing forwards and the lip of the rear seal facing rearwards 11 Assemble the rear piston Fit a grooved seal 03 3402 1901 1 into t...

Page 331: ... much preload will not allow the reservoir port to open Too little preload will allow free play and a rattle from the pedal Remove the locking grub screw 3 mm key in the end of the pedal trunnion apply Permabond A131 threadlock and refit loosley Screw the pushrod into or out of the trunnion until the pedal just contacts the pedal box flange upstop Apply Vz turn of preload to the pushrod and tighte...

Page 332: ...indrical coated alloy trunnions to actuate their master cylinder pushrods with the bore for the brake pedal trunnion being machined nearer to the pedal pivot than in that for the clutch pedal The top end of each pedal uses maintenance free self lubricating plastic pivot bushes and an extruded footpad is bolted or rivetted to the bottom end of the pedal The throttle pedal uses a ball jointed rod an...

Page 333: ...take hose from the diverter flap housing on the scuttle and release the screw securing the housing from within the intake aperture Move the housing aside to allow the pedal box fixings to be withdrawn 6 Remove the pinch bolts and disconnect and remove the steering column intermediate shaft 7 Remove the three M6 screws securing each end of the pedal box to the scuttle beam brackets and withdraw the...

Page 334: ...he pedal upstop for a throttle pedal height approximately 30mm lower than the clutch and brake pedals Adjust the length of the ball jointed pull rod to achieve a gap of 20mm between the outer cable abutment and the inner cable pivotting link on the multiplier lever Adjust the cable slack at the engine end abutment as detailed in section EMN or Lotus Check operating instructions Adjust the pedal do...

Page 335: ...ecuring the top guide bush to the caliper adaptor plate and withdraw the caliper from the car with the brake hose still connected d Slide out the lower steel guide sleeve and withdraw the bush boot from the caliper Pull the boots off the top steel guide bush and slide out the bush from the caliper e Clean the guide bores in the caliper body with brake cleaner Lubricate the new bushes and boots wit...

Page 336: ...NG SECTION KF M111 ELISE General Description Maintenance Drain Refill Procedure Radiator Cooling Fan Radiator Fan Control Radiator Feed Return Pipes Water Pump Thermostat Sub Section Page KF 1 3 KF 2 3 KF 3 4 KF 4 6 KF 5 8 KF 6 8 See Section EE ...

Page 337: ...matrix Heater feed pipe Engine outlet spout Cylinder head air bleed Radiator by pass circuit Thermostat housing Heater return water rail fk59l Thermostat Open Radiator Radiator outlet hose Radiator return pipe Radiator inlet hose Radiator feed pipe Engine outlet spout Radiator return rail Page 2 ...

Page 338: ...the heater return pipework When the thermostat is closed the radiator return circuit is shut off so that water is forced to flow through the heater and by pass circuits thus ensuring optimum heater performance The header tank is mounted at the left hand front of the engine bay with a hose from its underside connecting with the heater return rail near the thermostat housing An air bleed hose connec...

Page 339: ...e coolant at a known temperature using a hydrometer The following table provides a general guide Density Concentration 20 C 60 C 25 1 039 1 020 33 1 057 1 034 50 1 080 1 057 The coolant density reflects the effective level of mono ethylene glycol and not the level of corrosion inhibitors present whose effectiveness diminishes over a period of time The coolant should therefore be renewed every 24 m...

Page 340: ...he return water rail at the left hand side of the engine taking care not to misplace the sealing washer Water rail bleed plug I k60l 3 Using radiator pressure test equipment pressurise the header tank to circulate the coolant When neces sary refill the header tank and repeat When a steady stream of coolant flows from the bleed port replace the screw and washer and tighten Pressure test pump Page 1...

Page 341: ...uts in at 103 105 C and brings down the temperature to 90 95 C before the cycle repeats 7 Stop the engine and allow to cool fully before topping up the header tank to the low mark KF 4 RADIATOR COOLING FAN The aluminium cored radiator is mounted horizontally via four screws to a composite moulding which is itself secured to the top of the crash structure1 and also provides mounting points for the ...

Page 342: ...or from the radiator by removing the four nuts securing the fan shroud to the mount ing brackets rivetted to the radiator frame Withdraw the fan harness through the mounting panel grom met 7 Remove the four screws securing the radiator to the mounting panel 8 Refit the radiator in reverse order to removal and refill with coolant and bleed as detailed in sub section KF 3 Page 7 ...

Page 343: ...ormal running temperature the resistance will be approximately 300 400 ohms If the ECM receives a signal voltage outside of the acceptable range a default setting equating to 60 C will be substituted and the cooling fan energised To replace the sensor disconnect the harness plug and position a container to catch the escaping cool ant when the sensor is removed Unscrew the sensor from the junction ...

Page 344: ...he 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 4 Retrieve the two support foams from inside the chassis rail Fit the grommet into the hole in the chassis front closing plate and smear with rubber ...

Page 345: ...tion JH FUEL SYSTEM SECTION LH M111 ELISE Sub Section Page General Description LH 1 3 Fuel Filling LH 2 3 Precautions LH 3 4 Fuel Filter LH 4 4 Fuel Tank LH 5 5 Fuel Pump Sender Assembly LH 6 8 Charcoal Canister LH 7 10 Page 18 ...

Page 346: ... canister Solenoid valve Filler breather hose Throttle body purge port Pressure sensing hose to intake plenum Canister vent hose Pressure regulator valve Fuel injectors Fuel feed pipe Pump gauge sender unit Fuel return pipe Push fit connectors Iem208a I ...

Page 347: ...ting of the tank under normal circumstances but prevents fuel spilling from the vent pipe if the vehicle is inverted in an accident The evaporative emissions control system EECS prevents untreated fuel vapour from the tank reaching the atmosphere by routing the tank vent pipe from the roll over valve to a vapour storage charcoal canister mounted at the left hand side of the engine bay When the eng...

Page 348: ...his procedure should be used prior to disconnecting any part of the fuel line except the unpressurised return line Pull out the fuel pump fuse to rear of engine management ECM at LH side of rear luggage compart ment start the engine and run until it stops from starvation Crank the engine for a further 10 seconds If the engine is a non runner pull out the fuel pump fuse and crank the engine for a t...

Page 349: ... on the filter body which must point towards the engine 5 Start the engine and check for fuel leaks LH 5 FUEL TANK The fabricated steel fuel tank is mounted within the chassis crossmember between the engine bay and passenger compartment The tank must be removed from the chassis to allow replacement of the fuel pump gauge sender unit assembly To Remove Fuel Tank 1 Remove the left hand seat and from...

Page 350: ...o reduce the weight before removal 3 Remove the RH rear wheel and wheelarch liner and carefully peel back the cabin bulkhead sound barrier mat to provide access to the filler hose connec tions Release the filler hose and filler breather hose from the tank spigots and cap both orifices to prevent debris in gress and reduce the fire hazard Sound barrier mat Fuel filler hose Squeeze release tabs Fill...

Page 351: ...ase the throttle cable from the engine Release the gearchange cable and throttle cable P clips from the perforated shear panel below the fuel tank Release the fixings along the front and rear edge and remove the shear panel which closes the chassis box section housing the fuel tank Note that this panel is a structural part of the chassis and that the car should not be used without the panel fitted...

Page 352: ...rvation from surge effects caused by vehicle acceleration and cornering forces The complete unit is spring loaded against the bottom of the tank by three telescopic legs carried on the end plate which is clamped by a mounting ring and O ring to an aperture in the top surface of the tank The pump is housed within a reservoir canister kept filled with fuel even at very low tank levels The pump conne...

Page 353: ...ank from the chassis Electrical socket Outlet to fuel filter Return from regulator valve Telescopic legs Canister overflow Reservoir canister 3rd stage turbine Fuel level float Fuel tank Fuel return Pump motor 2nd stage impellor 1st stage impellor 2nd stage strainer Umbrella valves To Remove Pump Sender Assembly 1 Remove the fuel tank see sub section LH 5 2 Release the 8 x M5 fixing nuts noting th...

Page 354: ...ews A111W7163F with annealed copper washers A111W4170F Use Hylomar between the threaded ring and tank surface and apply thread lock to the screws before fitting with their washers and tightening to 4 0 Nm Fit the pump unit into the tank ensuring that the O ring is positioned correctly and align the pipe spigots on the end plate with the tank main axis pointing to the left Tighten the clamp ring nu...

Page 355: ...ft hand front corner of the engine bay via a tapered lug on the canister and corresponding bracket on the bulkhead Fuel vapour from the top of the fuel tank filler neck is routed via a roll over valve to prevent fuel spillage if the car is inverted mounted on a bracket integral with the filler neck to the canister port labelled tank A central tube in the canister connects this port to the undersid...

Page 356: ...rption Control System The canister purge valve is controlled by the engine management ECM which keeps the valve closed unenergised when the engine is cold or idling in order to protect the catalyst and maintain idle quality At coolant temperatures above 75 C and engine speeds above 1600 rpm the ECM opens the valve and allows purging of the charcoal to take place burning the resultant gas in the no...

Page 357: ...cation Fuse Ratings prior Oct 97 MN 4 15 Audio Equipment MN 5 17 Battery Battery Cables Earthing Points MN 6 18 Wiper Mechanism MN 7 21 Fitment of Driving Lamps MN 8 22 Harness Routing MN 9 23 Introduction of Uprated Starter Motor MN 10 28 Circuit Diagrams prior to Oct 97 white paper MN 11 29 Vehicle Security Alarm Cobra 6422 option MN 12 31 Fuses Relays Oct 97 onwards MN 13 36 Circuit Diagrams Oc...

Page 358: ...cally under certain conditions see below Passive Immobilisation Engine cranking and running are disabled automatically 30 seconds after the follow ing sequence of events The ignition is switched from on to off The driver s door is opened A warning that immobilisation is in effect is provided by the Alarm tell tale in the instrument pack flashing on once per second continuously lit if a door is ope...

Page 359: ...hat immobilisation is in effect is provided by the Alarm tell tale in the instrument pack lighting steady In order to mobilise the engine press once the embossed red transmitter button with the ignition key in any position the alarm tell tale will switch from steady to flashing illumination and the engine may be started If however the ignition is not switched on within 60 seconds passive immobilis...

Page 360: ... the siren but leave the system armed Press a second time to disarm Switching Off Interior Movement Sensing If an animal is to be left in the vehicle the alarm can be armed without the microwave sensor operating First arm the system in the usual way by pressing once the red button Then within 20 seconds press once the blue button This latter action will switch off the microwave sensor with an indi...

Page 361: ...te the system it will be necessary on the initial command to press the red button twice in order to synchronise the codes in the three elements Be sure to press the button for a whole second to allow the complete code to be transmitted Functional Test To test that the alarm system is operating correctly carry out the following test procedure 1 Arming the System a Ensure that the front bonnet engin...

Page 362: ...g Try to start engine Engine starts YES h Stop engine i Turn siren on with the override key siren will sound and disarm the system with the transmitter key press the red button twice for 1 full second each time Transmitter Battery Replacement Each of the transmitter keys is powered by a 12V battery type GP23 With normal use these should last between 6 and 9 months To ensure continuity of trouble f...

Page 363: ...mpartment The Lotus Check tool allows the following operations to be performed i Systems Check Not applicable on Cobra cars Checks door switches and immobilisation function ii ECM matching To programme the engine management ECM to recognise the coded signal from the 5AS security module in order to allow the immobilisation function to operate Necessary if either the engine ECM or 5AS module is repl...

Page 364: ...tool viii Press F2 Password Security System In order to control and monitor the security operations performed in the field using the Lotus Check a password system is used in conjunction with nominated supervisors at each dealership On receipt of the Lotus Check kit the accompanying Supervisor Password1 form should be completed and telefaxed to Omitech Instrumentation Note that the serial number et...

Page 365: ...ate and if either module is replaced the MEMS module must be programmed to recognise the signal Note that the last eight digits of the Vehicle Identification Number are required to be entered but that the third of these digits is called for as an alpha character rather than the actual numeric For this purpose disre gard the third character Transmitter Matching Not applicable on Cobra cars Each tra...

Page 366: ...hen the left hand or right hand turn indica m m m 0 ALARM L JJ c z tors are operating this green tell tale flashes in uni son The flasher relay may also be heard to operate If the tell tale fails to light or flashes at an unusual or irregular rate the operation of the turn indicator ES23 lamps should be checked immediately Parking Brake Tell Tale This tell tale will glow red with the ignition swit...

Page 367: ...he tachometer indicates engine speed in revolutions per minute Maximum safe engine speed is 7 000 rpm at which point the engine management system operates to cut off the fuel supply and safeguard the engine from overspeeding Do not run the engine continuously at its maximum speed or allow overspeeding to occur on the overrun by changing down through the gears too early as this imposes very high lo...

Page 368: ...ates with or without ignition Press a second time to switch off Master Lighting Switch A green tell tale window within the switch button is back lit illuminated when the ignition is switched on to help locate the switch Pressing the switch which operates with or without ignition will switch on the head lamps in addition to the sidelamps and panel illumination irrespective of the sidelamps switch p...

Page 369: ...im shroud ahead of the gear lever and is operative at all times To use the lighter press the centre button of the knob to activate the heating circuit When the element has been sufficiently heated which takes only a few moments the button will spring back out The lighter may then be withdrawn for use Care should be taken when handling the hot lighter to avoid contact other than with its target An ...

Page 370: ...ll make one sweep about every five seconds i Select the next position for normal wiper op eration Move fully upwards for quick wipe to be used only in heavy rain Wiper Washer Windscreen Washer Two windscreen washer jets are provided one each side of the wiper spindle Pulling the control lever towards the steering wheel will operate both the washer pump and the wiper When the switch is released the...

Page 371: ...n ind 7 5A Ignition services 8 7 5A Stop lamps batt serv 9 10A Hazard lamps 10 7 5A Horn 11 10A Alarm pwr int lamp 12 25A Cooling fan RHP shown D C B A Relays A Horn B Cooling fan C Dip beam D Main beam Fusebox B for cars Feb 97 on see also MN 10 Removal of the wiper motor cover two screws allows access to a second fusebox containing 4 Littel fuses and also to a pair of Maxi fuses Note that the or...

Page 372: ...ent components are detailed in Section EMN Fuse colours 2A Black 3A Violet 4A Pink 5A Orange 7 5A Brown 10A Red 15A Light Blue 20A Yellow 25A Clear Component Location Windscreen washer bottle Radiator fan motor Fusebox A relay station Fusebox B Wash wipe module Hazard relay Wheel speed y sensor Engine management ECM Engine management fuses DLC Horn Wiper motor Lucas 5AS security module Inertia swi...

Page 373: ...er panels need to be fettled to accommodate the se lected speakers Velcro Stowage net hook Speaker Speaker grille Seat belt real bolt Velcro Roll bar seat belt bracket Transformer Aerial The maintenance free trans former type flexible aerial is mounted on the engine cover and features an antenna mast which may by unscrewed by hand from its base if necessary to guard against vandalism All cars are ...

Page 374: ...ve the washer reservoir by pulling upwards from its mounting bracket To remove the battery disconnect both battery cables see below and pull off the breather pipe from the outboard end of the battery Release the three screws securing the battery clamp bracket to the chassis remove the clamp bracket and tilt the battery to release the lower edge from its retain ing channel Lift out the battery from...

Page 375: ...emoved to a well ventilated area to avoid a build up of fumes in the luggage compartment and to prevent damage to the car s electrical system Observe the safety precautions listed above when removing the battery Take care when handling the battery to avoid sharp knocks or shocks and keep as upright as possible Beware of the consid erable weight of a battery and take necessary precautions against p...

Page 376: ...he engine earth braid and rear harness earthing requirements At both points the anodised surface treatment must be removed from the chassis before an M8 Pulsert is fitted with a special stepped washer being used to clamp directly against the chassis surface After assembly coat the chassis and cable terminals with petroleum jelly to protect from corrosion Page 20 ...

Page 377: ... panel To remove the wiper mechanism 1 Release the front bonnet latch mechanism from the plinth integral with the motor wheelbox mounting bracket and disconnect the washer tubing 2 Remove the wiper motor protective cover by releasing the two screws into the windscreen buttress and the patch of adhesive between the inboard end and the screen gutter Disconnect the harness plug from the motor 3 Remov...

Page 378: ... the driving lamps which may therefore be retro fitted on any car if the air intake grille is also replaced Parts Required Description Driving Lamp Air Intake Grille Mounting Plate LH Mounting Plate RH Pulsert M8 mounting plate fixing Plastic Screw M8 x 25 plate fixing Washer plate fixing Plastic Screw M8 x 40 lamp to plate Spring lamp to plate Grommet lamp harness Part Number Oty A111M6008F 2 B11...

Page 379: ...enger side of the front services compartment forwards across the front of the chassis well to feed the heater motor horn and driving lamps and rearwards through the scuttle where it divides into branches running a through the scuttle beam and across the dash top for the instrument pack and switchgear and b along the cockpit centre tunnel to the rear of the car At the rear of the tunnel the harness...

Page 380: ...pack Lucas 5AS module Hazard wash wipe module Door switch connector Column switch connectors I m185l Cobra Alarm Harness RHD shown Immobilier touch key socket Lucas 5AS module connectors J03 m J o J01 2 7 Connector to siren unit Alarm controller Main harness connector Buzzer unit m187 Page 33 ...

Page 381: ...engine bay Engine management earth point Harness out of fuel tank bay Engine earth lead Chassis earth point Wheel speed sensor Main harness at ECM panel Rear harness connector DLC Engine management ECM Engine harness connectors Relay module Inertia switch ...

Page 382: ...Lotus Service Notes Section MN Rear clamshell harness Connector to main harness High mounted stop lamp Licence plate lamp Front clamshell harness I m19fl Connector to main harness I m197l Page 26 ...

Page 383: ...ervice Notes Section MN Centre tunnel harness routing Cigarette lighter terminals Rubber edging Foam pad Protective channel Into fuel tank bay Note use of P clips tie wraps and edge protection as shown Page 27 ...

Page 384: ...e for like basis Fitting a 1 4 kW motor on an earlier car may result in sufficient voltage drop to the engine management system to prevent starting Change Point The 1 4 kW starter motor was introduced at the following change point approx VIN V 685 February 97 Note that a label on the motor body identifies the type Fuse Location LH side of rear luggage compartment Early cars 1 0 kW motor engine man...

Page 385: ...ngine Management System 3 Alarm Immobiliser Lucas Interior Lamp Horn 4 Alarm Immobiliser Cobra Interior Lamp 5 Stop Reverse Lamps 6 Direction Indicators Hazard Lamps 7 Headlamps 8 Sidelamps Fog Lamps 9 Instruments 10 Windscreen Wipers 11 Interior Fan 12 Radio Cigar Lighter 13 Power Ground Structure 14 Inter Harness Connectors 15 Fuses 16 ...

Page 386: ... OTV Lotus Service Notes Section MN ...

Page 387: ...Lotus Service Notes Section MN J BATTERY S T A R T A L T E R N A T O R I G N I T I O N SHEET 387 ...

Page 388: ...FUSEBOX BATTERY IGNITION 1ST ART D R O P O U T IGNITION fUNFUSEDl IGNITION FUSE 01 b LEHC fa fa 2 4 T Tl 2 G a A eRiDGINO L INK O R C09RA IWM0B1L ISER V fa JEHC 9 P o 1 0 l J CD J 3 FJEL TiNK SENDS U St a EET 0 TP7WC Of 5TU0 8MM C D CD C H A S S I S IREAR1 i SHEET 2 ...

Page 389: ...Lotus Service Notes Section MN E N G I N E M A N A G E M E N T S Y S T E U S E B O X B A T T E R Y SHEET 3 ...

Page 390: ...Lotus Service Notes Section MN A L A R M I M M O B I L I S E R L U C A S SHEET 4 ...

Page 391: ...Lotus Service Notes Section MN A L A R M I M M O B I L I S E R COBRA SHEET 5 ...

Page 392: ...Lotus Service Notes Section MN S T O P R E V E R S E L A M P S SHEET 6 ...

Page 393: ... I N D I C A T O R S HAZARD L A M P S FUSE B O B A T T E R Y I G N I T I O N 5 T A R T D R O P O U T FUSEBOX I G N I T I O N U N F U S E O I I G N I T I O N FUSE Dl t t t o I f LO I uj HAZARD SWITCH 12V S10ELAMP5 SEE SHEET 9 H A Z A R D TlASHER SHEET 7 ...

Page 394: ...A Lotus Service Notes Section MN H E A D L A M P S SHEET 8 ...

Page 395: ...Lotus Service Notes Section MN S I D E L A M P S d FOG L A M P SHEET 9 ...

Page 396: ...Lotus Service Notes Section MN I N S T R U M E N T S SHEET 1 0 ...

Page 397: ...1 A Lotus Service Notes Section MN W I N D S C R E E N W I P E R S B A T T E R Y SHEET 397 ...

Page 398: ... Service Notes Section MN N T E R I O R FAN B A T T E R Y i o F U S E B O X I G N I T I O N START O R O P O U T I IGNITION UNFUSED I G N I T I O N FUSED in A FAN SPEED SWITCH R E S I S T O R SLOCK D SHEET 12 ...

Page 399: ...1 J Lotus Service Notes Section MN RADIO d CIGAR L I G H T E R SHEET 13 ...

Page 400: ...Lotus Service Notes Section MN i P O W E R GROUND S T R U C T U R E SHEET 14 ...

Page 401: ... R H A R N E S S C O N N E C T O R S FHC RHC m m c z m u f s l 7 8 E N G I N E H A R N E S S CONNECTOR I EH C dMJSli H E n i islEDUaiEi E N G I N E H A R N E S S CONNECTOR 2 EHC 2 E N G I N E H A R N E S S CONNECTOR 3 IEHC 3 n n 01H0I EELES i p 0 0 i n E H to 0 0 0 1 ALARM H A R N E S S M M O B I L I S E R C O N N E C T O R S AHC ICi 0 0 0 0 0 0 0 0 0 0 0 0 S H E E T 15 ...

Page 402: ... R V I C E S 08 7 5A STOP LANPS d BATTERY S E R V I C E S 09 1 OA HAZARD LANiPS 10 7 5A HORN 1 1 1 OA ALARM d INTERIOR LAfcP 1 z Z5A COOLING FAN FUSEBOX B NO R A T I N G A P P L I C A T I O N i 3 ZOA RADIO 1 4 ZCA CIGAR LIGHTER 15 5A S I D E L A M P S LH I 6 5A SIDELAIvPS RH FUEL PUMP FUSE n m H i i N 0 R A T I N G A P P L I C A T I O N i i i 1 OA FUEL PUM3 MAX I F U S E S TEE NO R A T I N G A P P...

Page 403: ...hes on both doors front bonnet and engine lid Selectable cockpit intrusion sensing using a hyperfrequency radar sensor Automatic passive engine immobilisation to prevent the engine from being started Self powered siren to maintain protection if the vehicle power supply is interrupted Dynamic coding of the transmitter keys Each time the transmitters are used the operating frequency is randomly chan...

Page 404: ...ilisation will be indicated by the alarm tell tale flashing and if initiated by the door being opened and closed two flashes of the hazard warning lamps Note that these indications are the same as those for the arming of the alarm but in this instance it is only engine immobilisation which is activated To start the car after immobilisation has been activated it is necessary to switch OFF the ignit...

Page 405: ...itter key buttons the transmitter key tell tale will blink and the alarm tell tale in the instrument pod will go out for one second 5 Repeat 3 and 4 for all other transmitter keys to be used up to a maximum of four When all keys have been programmed switch off the ignition alarm tell tale will go out Note that this programming procedure erases all existing transmitter codes so that all keys to be ...

Page 406: ...ter key is used to disarm the system if the alarm had been triggered during the armed period a diagnostic code will be displayed by the alarm tell tale until the ignition is next switched on The flash codes are interpreted as follows Single flash followed by 2 second break Caused by a door engine lid or front bonnet sensor A sensing switch may require attention Three flashes followed by 2 second b...

Page 407: ...n of Alarm Components Alarm controller on early cars may be fitted above passenger footwell Siren Touch key socket Siren connector LH side of rear luggage compartment Cobra immobiliser module Anti tamper cover Engine management ECM m225 Page 35 ...

Page 408: ...ent to the fusebox houses four relays protected by a clip on cover RHD shown D C B A Fuses Slot Rating Circuit 1 3A Rear fog lamp 2 2A Alarm ignition 3 20A Interior fan 4 15A Wiper motor 5 3A Reverse lamp 6 7 5A Direction ind 7 10A Ignition services 8 7 5A Stop lamps Slot Rating Circuit 12 25A Cooling fan 1 13 25A Cooling fan 2 air con only 14 20A Audio 15 20A Cigar lighter 16 5A Sidelamp LH 17 5A...

Page 409: ...er Cobra 6422 5A Stop Reverse Lamps 6 Direction Indicators Hazard Lamps 7 Headlamps 8 Sidelamps Fog Lamps 9 Instruments 10 Windscreen Wipers 11 Interior Fan 12 Radio Cigar Lighter 13 Power Ground Structure 14 Inter Harness Connectors 15 Fuses 16 Hot Soak Pump A C Cars 17 Cooling Fan Relay 2 A C Cars 18 Interior Fan A C Cars 19 Solenoid Valve Control A C Cars 20 A C Request Control Non Heater 22 C ...

Page 410: ... O R COBRA 1MM0BILISER CE z OS A 0 AvtHC ALTERNATE i6 H I C O IT STARTER yc GR ENGINE ENGINE I0N2 IGN CPANK BATTERY IGNITION I 5 T A R T O H O P O U T FUSEBOX IGNITION UN FUSE D G IGNITION f U S E O l 1 H C HC EHC C M C 3 6 r t 5A A 30 fl 3 Hs mulrI function y 2 s RELAY UNIT M P R U I 0 0 J 2 cn c j T i i SHEET ...

Page 411: ...Lotus Service Notes Section MN mm F U E L PUMP C O O L I N G FAN SHEET 2 ...

Page 412: ...Lotus Service Notes Section MN ENGINE MANAGEMENT S Y S T E M SHEET 3 ...

Page 413: ...TCRY L I G N I T I O N S T A R T Q R Q P O U T I f F U S E B O X I GN T I UN iUNFuSEDl T ION IT i ON IFUSED f L t Q 0 i c I n i A G N O S r i C CONNECTOR OBD2 1 o a z n z i SPl vt r I m i r j r C 5TAf T RE M S E SHEET 1 o P 3 0 5 T o I v Ar C A H C z 0 v El ds C MGR N o o o 10 pHC 0 STEER ING C QLU MN SHEET 4 ...

Page 414: ...Lotus Service Notes Section MN FUSEBOX F U S E B O X BATTERY SHEET 5 ...

Page 415: ...P O U T f L F U S E B O X I G N I T I O N UNFUSED f I G N I T I O N FUSED f I o o l 1 X CO r J T O INSTRUMENT PAC S E E SHEET 1 0 T t o H 0 P J RELAY SMtET 4 0 D AGNOSTIC vClKECOR sEE S H E E T 3 EMC i IC c PHC 1 L AMP I P T rs T p HC RHC _ Trine T A N REVERSE LAVPS u s e d UN MAL A f 3 1 AN CARS ONLY SHEET 6 ...

Page 416: ...mm Lotus Service Notes Section MN D I R E C T I O N INDICATORS H A Z A R D L A M P S SHEET 7 ...

Page 417: ...Lotus Service Notes Section MN H E A D L A M P S SHEET 8 ...

Page 418: ...Lotus Service Notes Section MN S I D E L A M P S FOG LAMP SHEET 9 ...

Page 419: ...Lotus Service Notes Section MN I N S T R U M E N T S S H E E T 10 ...

Page 420: ...Lotus Service Notes Section MN W I N D S C R E E N W I P E R S BATTERr SHEET 420 ...

Page 421: ... Notes Section MN I N T E R I O R F A N B A T T E R Y t i FUSEBOX I G N I T I O N START O R O P O U T I G N I T I O N I U N F U 5 E 0 I I G N I T I O N I F U 5 E 0 a1 O1 6 w 6 v w x R E S I S T O R BLOCK c SHEET 12 ...

Page 422: ... B O X B A T T E R Y i o 1GN IT ON S T A R T D R O P O U T F U S E B O X I G N I T I O N UN F U S E D I G N I T I O N F U S E O 1 0 1 cc A E R I A L 12V SIOELAMPS S i t SHEET 9 0 V RADIO s w VJ CI34R LIGHTER RB HZV SIOELAMPS SEE SHEET 9 S E A E R 5 EAKER _L SHEET 13 ...

Page 423: ...WER GROUND S T R U C T U R E O F H C I G N F 1 0 N SWITCH HEADLAMP CIRCUIT ENGINE MANAGEMENT F R O N T H A R N E S S C O N N E C T O R A L T E R N A T O R E N G I N E R E AR h AR N E 5 5 rCNNECT 0R X x O F J E L PUMP ORHC S H E E T 14 ...

Page 424: ...EE ex m mmm FRONT D R E A R H A R N E S S C O N N E C T O R S FHC RHC I m m a m cm mmm 0 B 0 0 0 0 0 2 ENGINE H A R N E S S CONNECTOR EHC ENGINE H A R N E S S CONNECTOR 2 IEHC 2 ma EN NNR C NE H A R N E S S OR 3 EHC 3 nisi IT S ALARM H A R N E S S 4 MCE IL I S E R C O N N E C T O R S IAHC C 0 0 aE E 0 0 0 0 0 0 0 S H E E T 15 ...

Page 425: ...Y S E R V I C E S 03 CA HAZARD L A W S 1 0 SA U T R N J 1 OA ALARM I CR L A W I S A CCOLLNG FAN I 3 25A X C L I V C AN 1 4 OA A 0 T 1 5 OA C GAR LIGHTED 16 5A S I CTI_AW LH 1 7 5 A S T C E L I P RH 8 OA A C C L l H L 9 5A V I X U L E o Z C J AN S EED PELAR i 1 A C E Q U I P E D V E H I C L E 5 ONLY A C E Q U I P E D V E H I C L E S ONLY A C E Q I K P E D V E H I C L E S ONLY A C E Q L i P E D V E ...

Page 426: ...S F U S E B O X S P L I C E C B A T T E R Y O T H O I G N I T I O N I S T A R T O R O P O U T l I G N I T I O N U N T U S E O l S P L I C E B i g n i t i o n F u s e d i V in ON 3 o K 4 3 D 0 HOT SOAK S ITCH o o XL CL SI S P L ICE T S P L I C E T o SHEET 17 ...

Page 427: ...tion MN C O O L I N G F A N R E L A Y 2 A C C A R S F U S E B O X B A T T E R Y i I G N I T I O N f S T A R T D R O P O U T l I G N I T I O N U N F I J S E D I I G N I T I O N F U S E D C H A S S I S i f l E A H i Q SHEET 18 ...

Page 428: ...Lotus Service Notes Section MN i j I N T E R I O R FAN A C C A R S SHEET 19 ...

Page 429: ...VALVE C O N T R O L A C C A R S BAT T E R Y I G N I T I O N I S T A R T O R O P O U T O I G N I T I O N U N F U S E D S P L I C E 6 S P L I C E B I G N I T I O N F U S E D a S O L E N O I D G R E C I R C U L A T I O N S O L E N O I u C S H E E T 20 ...

Page 430: ... I T I O N F U S E 0 t V oo o A C CLUTCH RELAY L GU L G U T FAN SPEED SWITCH SEE SHEET 19 AC C O M P R E S S O R C L U T C H 1 c n A C REQUEST RELAY QPOOQO 5 SB KB R U ACU C O N T R O L M O O U L E TV P e UR X ACU T E M P C O N T R O L ACU T H E R M I S T O R A C O N O F F SWITCH GK ft 3 12V SIDELAMPS G K BR I Do I NO LINK AC CONT SOL f o A C R A D CAON1ROL KU E C LI ME MS 1 9 BO 35 5 SHEET 22 ...

Page 431: ...Lotus Service Notes Section OG MAINTENANCE LUBRICATION SECTION OG M111 ELISE Page Recommended Lubricants 2 Maintenance Schedule 4 Pre Delivery Inspection 7 1998 OS Page 1 ...

Page 432: ...ion API SG or SH should be used Note that the viscosity rating is made up of two numbers the first identified by a W suffix is the winter or low temperature viscosity grade and the second number the summer or high temperature viscosity grade i e a 20W 50 oil performs like an SAE 20 oil at low temperature and an SAE 50 oil at high temperature Engine Oil Viscosity Chart Viscosity Ambient Temperature...

Page 433: ...clutch Fluid change interval Engine Coolant Additive Type Concentration System capacity Coolant change interval Non mineral non petroleum hydraulic fluid DOT 4 1 5 litre 0 5 litre 12 months Unipart Super Plus Anti Summer Coolant 50 8 0 litre 24 months 1998 ns Pane 3 ...

Page 434: ... The approval of the customer should be obtained before any extra work is undertaken details of which should be recorded in the space provided at the end of the schedule After Sales Service There is no charge to the vehicle owner for the labour content of the After Sales Service Only materials used will be charged Inspect means assess condition and test for correct operation Extra time is required...

Page 435: ...ooling System 12 Inspect radiator hoses pipework for damage or leaks Clean radiator finning X X X 13 Check coolant level X X X X 14 Renew coolant 12 months Braking System 15 Inspect parking brake adjustment X X X X 16 Inspect operation of brake tell tales X X X X 17 Inspect brake pad thickness disc condition A X X X A In conditions where the brakes are subject to heavy use inspection may be requir...

Page 436: ...eck plate X X X X 32 Inspect operation condition of seat belts X X X 33 Top up screenwash reservoir X X X X 34 Renew alarm transmitter batteries check with customer 24 months Road Test Performance Engine performance Tailpipe CO Clutch operation Gearbox operation Brake performance Steering performance Driveline suspension noise vibration Wheel balance General comments Additional work required Work ...

Page 437: ...Check headlamp alignment X X Check operation of horn s hazard switch X X Check wiper operation at all speeds park position X X Check washer operation jet alignment reservoir level X X Check operation of all instruments set time clock X X Reprogramme door window switches X Check operation of heater air conditioning and blower fan X X Check operation of door mirror controls heaters X Check operation...

Page 438: ...n both Esprit and Elise models Spoiler fosn Esprit Oil cooler undershield Elise Mounting plinth Road Test Performance Engine performance Brake performance Clutch operation Gearbox operation Steering performance Wheel balance Driveline suspension noise vibration General comments Additional work required Work completed by Notes The PDI is subject to the following conditions a It is the responsibilit...

Page 439: ...Lotus Service Notes Section PF HEATING VENTILATION SECTION PF M111 ELISE Sub Section Page General Description PF 1 2 Control Cables PF 2 4 Heater Matrix Blower Fan Unit PF 3 7 Page 439 ...

Page 440: ...ite crash structure bonded to the front of the chassis A pair of holes in the chassis front crossmember mate with these tubes and admit air into the heater unit on either side of the heater matrix The heater matrix is a water air heat exchanger mounted vertically in a plastic moulding housed in the space between the front ends of the chassis rails in the front services compartment and is fed with ...

Page 441: ...ter matrix Heater return pipe Thermostat housing Heater return radiator by pass rail Distribution flap housing Convoluted ducting Footwell vent adaptor Matrix housing rubber strap Matrix air feed adaptor Heater matrix Air inlet collector Blower fan unit Temperature flap matrix housing Page 441 ...

Page 442: ...nd a duct moulded into the underside of the fascia top which supplies all four fascia vents PF 2 CONTROL CABLES For access to the heater controls and input end of the cables the dash panels must be dismantled 1 Release the four screws securing the steering column shroud upper section turning the steering wheel as necessary to permit access 2 Pull out the grommet from around the ignition switch and...

Page 443: ...e cable which connects to the heater or distribution flap spindle via a lever with a boss and grub screw The lever is equipped with three holes for use in different applications Control lever 6 The heat control cable runs forward through the scuttle blanking panel and down to the heater matrix housing in the chassis front well Hook the inner cable into the outermost hole in the temperature flap le...

Page 444: ...ndle and clamp the outer cable to allow full flap movement to be obtained RHD viewed from beneath Distribution control cable Distribution flap lever Spring clip Footwell outlet vent I3E LHD cars The cable connects to the top end of the flap spindle with access improved by the removal of the wiper mechanism With the selector lever at defrost the flap spindle should be turned fully clockwise and the...

Page 445: ...gs and is clamped to the blower fan unit by a rubber strap The complete assembly is secured via thread inserts in the chassis front well by two screws through a bracket on the front of the fan unit and a single screw through the fan casing at the rear accessible after removing the outlet ducting An additional screw secures the heater matrix inlet moulding via a bracket on the top front edge Page 4...

Page 446: ... lever 4 Release the two hoses from the matrix inlet and outlet connections and immediately plug to reduce coolant loss 5 Remove the four screws securing the matrix blower fan assembly to the chassis and withdraw the com plete unit 6 Unhook the rubber strap to separate the matrix and mouldings from the blower fan unit 7 Re assemble in reverse order to the above noting that on LHD cars a spacer is ...

Page 447: ...5 Vacuum Control System PH 3 9 A C Clutch Cooling Fan Control PH 4 12 Coolant Re circulation Pump PH 5 12 Refrigerant Handling PH 6 13 Refrigerant Pipework Precautions PH 7 14 Refrigerant Oil PH 8 16 Compressor PH 9 16 Condenser PH 8 16 Receiver Drier PH 11 20 Expansion Valve PH 12 21 Evaporator Unit PH 13 22 Heater Blower Fan Assembly PH 14 23 Exige A C Circuit Diagram 24 2000 04 Page 1 ...

Page 448: ...f RH chassis siderail Water valve Water return pipe along outside of LH chassis siderail Water return to engine side of thermostat Coolant re circulation pump Receiver drier Feed return pipes along outside of RH Service valves Condenser Expansion valve Evaporator Page 2 2000 04 ...

Page 449: ...refrigerant circuit should not be opened unless absolutely necessary and only then using appropriate refrigeratant recovery equipment Never allow the refrigerant to vent to atmosphere Refer to sub section PH 5 Failure to observe these precautions may result in personal injury Compressor When the engine is running and the refrigeration controls demand it the electromagnetic clutch incorpo rated in ...

Page 450: ...l ahead of the passenger compartment footwell All incoming airflow is directed through the evaporator before being directed through or around the heater matrix through the blower fan and into the air distribution chamber The low pressure liquid refrigerant flowing into the evaporator via the expansion valve begins to boil evaporate and in so doing draws the necessary heat for this process from the...

Page 451: ...ive Air Re circulation When the re circulation button is pressed a vacuum operated flap via a solenoid valve closes off the fresh air intake and opens the recirculation port to draw air from the interior of the car via the four groups of holes in the chassis footwell front wall This facility should be used when maximum refrigeration is desired or in heavy traffic to minimise the induction of exhau...

Page 452: ...h a solenoid valve and pneumatic water valve closes off the hot water supply to the matrix The water valve is located at the bottom right hand side of the engine bay If air cooling is required use this temperature position in conjunction with air conditioning Turning the control progressively clockwise moves the air blend flap to direct an increasing proportion of the airflow through the heater ma...

Page 453: ... on the floor of the unit to control airflow to the footwell vents The default position of the flap is to close the footwell vent with vacuum being required to open the port Screen A vacuum actuator mounted externally on the passenger side of the plenum is connected via two rods and a bellcrank lever to a screen flap which controls airflow into the demist duct to which the plenum is mated The defa...

Page 454: ...ion air is supplied to the windscreen footwell and face level vents Each of the wind screen outlet vents may be manually rotated and directed as required To boost airflow from the windscreen and footwell vents close off the face level vents using their individual thumbwheels Footwell and screen solenoids energised vacuum opens footwell flap vacuum shut off from screen flap which opens Windscreen A...

Page 455: ...is equipped with an electrical micro switch closed at the full cold position to operate a solenoid valve and supply the water valve actuator Note that the default position of the flaps no electrical power or vacuum supply is screen flap open footwell flap closed fresh air intake open The water valve default is open The vacuum pipes from reservoir to solenoid valves and from water valve soleinoid v...

Page 456: ...arness tag footwell Screen flap solenoid To screen flap actuator To footwell flap actuator Vacuum supply to solenoid centre spigots To re circ flap actuator To water valve Vacuum reservoir Inlet port to engine Shown with RH rear wheelarch liner removed Outlet port to solenoid valves O D Page 10 2000 04 ...

Page 457: ...follows Switch terminal C L M H Cable colour Green Green Black Green Purple Green Orange Function Ignition supply Footwell flap Footwell sceen flaps Screen flap Fed at switch position All Footwell Footwell Screen Screen Note that diodes in the green purple circuit isolate the footwell and screen flap actuator circuits from each other at control positions other than footwell screen 2000 0 4 Page 11...

Page 458: ... reach 108 C When the trinary switch on the receiver drier indicates that a c is operating and that condenser cooling is required the fans will operate at fast speed regardless of coolant temperature Engine Malfunction If the engine ECM detects certain types of engine malfunction including misfire or anomolies in coolant temperature or intake air temperature the cooling fans will be switched to fu...

Page 459: ... the pipe between the evaporator and compressor the high pressure liquid line port is fitted in the pipe between the compressor and condenser 3 Heavy concentrations of refrigerant vapour can produce toxic gas if exposed to a naked flame The gas can also attack metal 4 Refrigerant drums must never be left open always ensure the caps are securely fitted 5 Never transport drums of refrigerant in the ...

Page 460: ...by the slightest imperfection Always use two spanners of the correct size when releasing or tightening any pipe joint so that the fixed part of the union may be pre vented from twisting and damaging the component This is especially important with the aluminium condenser 6 All pipes and hoses must be free from any kinking The efficiency of the system can be impaired by a single kink or restriction ...

Page 461: ...Lotus Service Notes Section PH REFRIGERANT PIPEWORK TORQUE CHART rpTgn 2000 04 Page 15 ...

Page 462: ...re assembly see section PH 7 If a refrigeration component is to be replaced the removed item will contain a certain amount of oil and a corresponding amount of new oil must be added to the system on re assembly Condenser 30 cm3 Evaporator 30 cm3 Any major pipe or hose 10 cm3 Receiver drier 30 cm3 Approved Oils Use a refrigerant oil from only the following list Seiko SK 20 Unipart SK 20 Idemitsu SK...

Page 463: ...wheel and engine bay undertray if fitted Access to the compressor mounting bolts and pipe connections will be improved if the engine mounting tie bar at the back of the engine is released and the engine is moved backwards slightly 3 Release the pipe support clamp adjacent to the service ports and from beneath the car release the suction and discharge pipes from the compressor and immediately cap t...

Page 464: ...of oil before refitting and tightening the plug ii If the system has suffered a rapid discharge caused for example by accident damage most of the refrigerant oil will have been lost In this case the 170 cm3 of oil contained in the new compressor is to be retained Compressor Fitment 1 Fit the compressor to the engine with the drive belt positioned and secure with the three M10 bolts Tighten to 43 4...

Page 465: ...ing frame from the radiator The condenser is supported in the frame by four spigots in rubber grommets 9 Refit the condenser in reverse order to removal with the following notes If a new condenser is to be fitted add 30 cm3 of approved refrigerant oil to the system Use new O rings on the pipe connections and lubricate with refrigerant oil Using two spanners tighten the condenser inlet connection t...

Page 466: ...unted on the RH side of the front crash structure and houses the trianry switch If the switch or receiver drier is to be replaced the refrigerant must first be recovered using suitable equipment connected to the service ports at the right hand front of the engine bay Cap all pipes and ports immediately after disconnection to prevent the ingress of dirt and moisture When reconnecting the pipes use ...

Page 467: ...m the valve Immediately cap the pipes and ports to prevent the ingress of dirt and moisture 3 Release the two M5 screws securing the valve to the evaporator pipes and withdraw the valve from the pipes Immediately cap the pipes and ports to prevent the ingress of dirt and moisture EE 4 Before refitting renew all the connector O rings and coat with an approved refrigerant oil 5 Fit the threaded clam...

Page 468: ...the refrigerant Remove the a c pipe between expansion valve and receiver drier and between expansion valve and sill connector block 5 Disconnect the harness connector to the thermostatic switch and the vacuum pipe to the intake flap actuator 6 Ease the evaporator unit out of the chassis 7 Before refitting the unit in reverse order to the above first check that the battery earth cable is correctly ...

Page 469: ... releasing the two heater hoses from the matrix and plugging both hoses to minimise coolant loss 3 Remove the trunking between the fan scroll and distribution plenum 4 Disconnect the blender flap control cable from the flap lever and abutment and unplug the fan harness connector 5 Release the single fixing securing a bracket on the top rear of the unit to the chassis and withdraw the unit from the...

Page 470: ...Lotus Service Notes Section PH A C EXIGE CIRCUIT 25 07 00 EC A C REQ CLUJCH OIP Page 24 2 0 0 0 04 ...

Page 471: ...Lotus Service Notes Section OG CLUTCH SECTION QF M111 ELISE Sub Section Page General Description QF 1 2 Adjustment QF 2 3 Hydraulic Release System QF 3 4 Clutch Assembly QF 4 9 ...

Page 472: ...Lotus Service Notes Section QF C 0 E 0 O c CO C O 2 0 0 E 0 iff o 3 o Q 1 3 Page 2 1998 02 ...

Page 473: ... sleeve surrounding the gearbox input shaft A preload spring inside the slave cylinder applies light pressure to the release lever in order to ensure that contact between the release bearing and diaphragm spring fingers is maintained QF 2 ADJUSTMENT No routine adjustment of the clutch or release mechanism is required The clutch slave cylinder is self adjusting with the rest position of the piston ...

Page 474: ...ked via hose to the adjacent brake fluid reservoir Input pushrod Pedal Brake master cylinder reservoir Fluid reservoir hose Outlet pipe Fixing Clutch master cylinder To replace the master cylinder Clean the master cylinder and surrounding area with methylated spirit Do not use petrol or paraffin Take all necessary precautions to guard against contamination of painted surfaces with brake fluid Disc...

Page 475: ...ll parts Clean all parts thoroughly with only new brake fluid and dry with a lint free cloth Carefully examine the cylinder bore for scoring corrosion or visible wear and replace if any such signs are apparent Check that all drillings in the cylinder body and piston are clear If the cylinder is serviceable rebuild the unit using new seals and components from the appropriate overhaul kit Note that ...

Page 476: ...e of the cylinder body Use a suitable rod to operate the piston by hand several times to check for free movement of the internal parts Refit the cylinder as detailed above Slave Cylinder The slave cylinder is secured by two bolts to a mounting bracket on the transmission and is connected to the clutch operating lever by a fixed length pushrod and clevis pin A sleeve nut is used to connect the flex...

Page 477: ...ial Clean hands thoroughly beforehand Lubricate the seal the cylinder bore and all internal components with clean brake fluid Fit the seal into its groove on the piston with the lip towards the closed end of the cylinder Insert the spring and piston assembly into the cylinder taking care no to bend back the seal lips Pack the inside of the dust boot with rubber grease and seat the lip of the boot ...

Page 478: ...id contamination of painted surfaces 3 To ease withdrawal of the pipe straighten out the right angled connector at the rear end of the pipe and reaching into the rear end of the sill remove as much of the foam sleeving from the pipe as can be accessed Remove the grommet from the scuttle baffle panel 4 On LHD cars Securely attach a draw wire to the rear end of the pipe and withdraw the pipe from th...

Page 479: ... lift 1 Remove the LHR lower wishbone Release the bolt securing the spring damper unit to the lower wishbone Release the wishbone to chassis pivot bolts Release the parking brake cable ties and swing the wishbone out of the way 2 Release the RHR suspension toe control link from the hub carrier and release the top ball joint plinth from the hub carrier taking note of the camber adjustment shimplate...

Page 480: ...ng the clutch housing to the engine 2 bolts to the sump 1 bolt each side through the block lower wings 2 bolts securing the top of the clutch housing to the engine 12 Pushing the engine to the right and downwards at the flywheel end withdraw the transmission from the engine Inspection of components 13 Before removing the clutch cover from the flywheel place a flat plate over the ends of the diaphr...

Page 481: ...replaced as a precaution regardless of inspection results 17 Check the surface condition and run out of the flywheel friction surface see section ED 14 and replace the flywheel if necessary 18 Withdraw the release bearing and examine for signs of wear damage or roughness and replace if in doubt 19 Examine the condition of the clutch release fork pivot shaft bushes and oil seal see transmission rep...

Page 482: ... into the transmission by pulling on the inboard joint bodies Use a new O ring on the speedo drive cable and lubricate on assembly Renew the two topmost bell housing to engine patchlock bolts or apply a suitable threadlocking com pound if re using original bolts Use special tool T000T1390 to protect the output shaft seals during driveshaft refitment see sub section FH 5 Engine Transmission Fixings...

Page 483: ... 8 18 Front Hub Clamp Bolt Set XA 9 21 Adjustable Front Anti Roll Bar XA 10 22 Oil Cooler Kit XA 11 23 Battery Isolator Switch XA 12 26 Removable Steering Wheel XA 13 31 Stage 2 135 bhp Engine Tuning Kit XA 14 33 Yokohama A038 R Competition Tyres XA 15 35 340R 340 PS Tonne Pack XA 16 36 340R Oil Cooler Kit XA 17 40 Goodridge Brake Hose Set XA 18 42 5th Point Seat Harness Kit XA 19 42 Rear Raceligh...

Page 484: ... 50 fully synthetic after running in on a good quality mineral oil Output Max power 190 ps 7 500 rpm Max torque 189 Nm 5 600 rpm The engine is supplied only as a complete assembly for competition use and does not carry the normal vehicle or parts warranty Included in the engine package are Engine harness and new ECM with matched security 5AS module Exhaust manifold unchanged Inlet manifold throttl...

Page 485: ...rap A082W6324F 2 Clip fuel pipe support C clip A082W6587F 2 Oetiker Clip fuel return hose B082K6060F 1 Fit the new fuel feed pipe to the left hand end of the fuel rail smearing the O ring with silicone grease and tightening the two fixing screws to 4 Nm Fit the return hose to the RH end of the rail and secure with the Oetiker clip Secure the hose using the two C tie wrap clips to the header tank w...

Page 486: ...23K 1 Remove the new air cleaner element from the backplate by releasing the four socket head screws Oil the filter ele ment with the ITG aerosol to give an even coverage then gently massage the oil into the depth of the foam Feed the air cleaner element into the new airbox fit the airbox onto the backplate and secure the airbox and cleaner with the four screws Remove the existing profile adaptor ...

Page 487: ...or the oil pressure switch 9 Refit the clutch and transmission sub section QF 4 to the engine and fit the complete power unit back into the car sub section EE 3 Note that the luggage bay bulkhead is not re fitted 10 Fit the new throttle cable A111J0140S to the engine connecting to the linkage between the two throttle bodies and route as previously to the pedal box 11 At the pedal box check the spe...

Page 488: ... the cable at the throttle body abutment to allow full throttle to be attained If necessary adjust the pedal upstop and pedal pullrod length Ensure that the pedal downstop is set to protect the cable from strain at full throttle 13 The engine is supplied with a new ECM together with a matched security 5AS module If the car is to be used in competition it is recommended to disable the passive immob...

Page 489: ...before use see installation procedure 2 The filter must be cleaned regularly dependent on operating conditions Cleaning can be carried out using a bath of petrol or with liquid detergent and warm water Rinse in warm water after cleaning Do not use hot water After cleaning the filter should be allowed to dry thoroughly Do not use a high pressure air line or a hot air blower 3 After cleaning the fil...

Page 490: ...s or in conjunction with the roll over bar reinforcement kit the 6 point Competition Harnesses The Kruss Competition Harness uses 70mm wide shoulder straps wrapped around the roll over bar reinforcing frame 70mm lap straps and 50mm crotch straps all of which plug into a single buckle with a bi directional lever release The installation of the harness is illustrated overleaf for both seat types Pay...

Page 491: ...Lotus Service Notes Section XA COMPETITION SEAT P a n o ...

Page 492: ...1 1 Lotus Service Notes Section XA COMPETITION STYLE SEAT Special stud Page 10 ...

Page 493: ... pan pozi corner plate to floor A075W5095F 2 Washer M8 A075W4079F 2 Nut M8 A907E6284F 2 Setscrew M8 x 16 corner plate to chassis side rail A075W1036Z 2 Washer M8 A075W4079F 2 Nut M8 A907E6284F 2 Grommet chassis side rail access hole A111A6003F 1 Fitting Procedure 1 If fitted remove the following Roll bar fairing and rear window Both audio speaker panels Both inertia reel lap and diagonal seat belt...

Page 494: ...g the U bracket over the roll hoop and A frame apex Fit and tighten the bolt clamping the U bracket to the A frame 9 Mark the position of the top and bottom holes in the U bracket and comer plate tubes against the strut spigots Release the U bracket from the A frame and hoop and withdraw the bracing strut Drill the marked holes in each spigot to 9 mm diameter Refit the bracing strut and U bracket ...

Page 495: ... U end spigot M8x 50 Front suspension lower wishbone Roll hoop Harness bar end spigot Harness bar fixing point ...

Page 496: ...ing holes in the crossmember as shown in the diagram 2 Drill the two holes 9 0 mm diameter through only the top surface of the crossmember 3 Insert the two Rivnuts and use an M6 threaded puller tool or appropriate M6 slave screws to crimp the two Rivnuts into position 4 Fit the extinguisher mounting bracket using the two countersunk M6 screws provided and clip in the extinguisher Chassis side rail...

Page 497: ...us Elise The bottle is secured to the passenger floor crossmember using threaded inserts A release handle is mounted in the fascia and externally on the front wing Extinguisher nozzles are mounted in the cockpit and at both sides of the engine bay Pay close attention to any fitting instructions supplied with the kit and check any specific requirements of competition events Page 15 ...

Page 498: ...mm Lotus Service Notes Section XA Page 16 ...

Page 499: ...he pivot bolt before marking up the four fixing hole positions on the chassis rear subframe At the outboard end of the link a milled aluminium bracket is bolted to the bottom of the hub carrier utilising two of the lower ball joint plinth fixings The pivot boit uses a sliding sleeve in the lower leg of the bracket to avoid any bending stress in the bracket when the bolt is tightened Note that each...

Page 500: ...mmended to be fitted with this kit are Front hub bearing clamp bolt set A111C0137S applicable to cars prior to VIN V 1830 Sept 97 Rear Uniball toe link kit A111D0127S Adjustable uprated front anti roll bar A111C0134S The springs dampers and rear top damper mounting brackets with spreader plates are direct replace ments for the standard parts The dual rate front springs are fitted with the close co...

Page 501: ...s it moves towards bump with roll A shim stack is provided at the outboard end of the toe link by which the joint height in relation to the wishbone pivots may be adjusted A basic stack dimension detailed below will provide an approximately correct geometry but in order to optimise the characteristic accurate individual wheel alignment equipment or a dedicated bump steer gauge must be used to meas...

Page 502: ...g but the base setting of the shim washers is the same for standard 140mm and race 100 110mm ride heights Note The standard toe link with female threaded pivot balls requires a very specific assembly configuration with different bolt lengths and washers used for different shim pack thicknesses Refer to sub section DE 4 for full details If a car with this joint type is found to require more than 5 ...

Page 503: ...F 2 A111W3159F 2 A111C0117F 2 A111C0118F 2 B111C0076F 2 A111W4171F 2 The M16 clamp bolt set is a direct replacement for the M12 set and it is recommended that at the time of fitting the hub is removed from the bearing and the condition of the hub spigot carefully examined If any signs of bearing inner race movement on the hub are evident the hub and bearing should be renewed and assem bled with th...

Page 504: ...ber mounts introduced in March 98 For later cars discard the rubber mountings and order sepa rately the Nylon mountings and associated fixings Notes The top hat spacer bush in the Nylon block should be fitted with the flange abutting the chassis Lubricate the bar to Nylon block using MoS2 grease Tighten the wishbone pivot bolt and anti roll bar drop links to 45 Nm Lower Wishbone Front Pivot Detail...

Page 505: ...the RH sill and front wheelarch Oil Cooler Kit Contents Description Oil Cooler Kit comprising Oil Cooler Oil Filter Housing 90 Connector oil pressure switch Hose oil cooler feed Hose oil cooler return Mounting Bracket oil cooler Duct oil cooler Undertray front Convolute Hose Protector Grommet cooler hose Miscellaneous Fixings Part no A111K0037S A111K0036F A111E6146F A111E6147F A111K0035F A111K0034...

Page 506: ...hell and undertray Mark up and cut the air inlet holes in the floor of the crash structure as shown in the diagram and also the hose routing holes in the RH side of the structure Fit grommets into the hose routing holes Air inlet holes in crash structurefloor 83 mm diameter holes 140 140 I CM O Cooler hose holes in crash structure RH side Towing strut fixing holes 30 mm holes for cooler hoses 6 5 ...

Page 507: ...m holes for cooler hoses x20 6 Use convoluted hose protection at the rear end of both hoses where they exit the sill area connect the hoses to the unions on the oil filter housing and tie strap to the adjacent water hose and or together as necessary Fit a grommet onto each hose and locate in the A post holes 7 Feed the hoses through the side of the crash structure and fit the grommets into the hol...

Page 508: ...0129S 1 comprising Switch Box Assembly prior revised harness A111M0126S 1 Switch Box Assembly revised harness A111M0125S 1 Master Switching Relay A111M6087S 1 Bowden Cable A111M6088S 1 Battery Positive Link Cable A111M0109S 1 Miscellaneous Parts New harness introduced at VIN W 1941 Plus 1920 1926 1937 1938 Less 1965 2002 Component Siting 1 Switch Box Assembly Position the switch box on the car cen...

Page 509: ...e casing Secure the cable to the dash underside with a Vy clip as shown Bowden cable handle Alternator dump resistor Route cable through panel Drill new 9 mm hole Electrical Connections 1 Disconnect battery negative cable first 2 Replace existing 8mm eyelets on battery positive cables with 6mm eyelets using crimp and solder tech niques 3 Fit new masterswitch relay into the battery well as shown in...

Page 510: ...minal from this cable and use splice crimp solder and heatshrink to connect with the unterminated green cable from the new switchbox Insert the terminated green wire from the new switchbox into the vacated fusebox cavity 7B Replace fuse 7 1 OA and refit the fusebox i Bowden cable Prior to revised harness Operating switch Switchbox Green to new fuseholder Unterminated black to alternator dump resis...

Page 511: ...o connect cavity A to the master switch terminal with the battery positive link A111M0109F attached 9 Insert the terminated black cable from the operating switch into cavity B of the two way connector on the masterswitch relay 10 Connect the ring terminated black cable from the operating switch to the battery negative terminal 11 Reconnect battery 12 If the car is to be used in competition and the...

Page 512: ...B VEHICLE BATTERY O O BOVDEN MANULE PULL CABLE i i IGN SVITCH B o 7 5 IR SIEMENS RELAY B 5 rUSE A7 MASTER SWITCH 20 10 A G 7 FUSE BOX A MAXIFUSES STARTER MOTOR 0 17 V 20 ALTERNATOR DUMP RESISTOR B 4 C075 OPERATION SVITCH IN OFF POSITION G 6 IGNITION SERVICES E3 Page 30 ...

Page 513: ...rrier 3 Assemble the new wheel assembly Fit the horn contact adaptor into the locking ring with the alignment pip and notch engaged Secure the steering wheel spacer ring to the locking ring with six countersunk screws using a suitable thread lock Fit the steering wheel to the spacer ring with six countersunk screws using a suitable thread lock Connect the two leads to the new horn push red to cent...

Page 514: ...Lotus Service Notes Section XA Horn slip M6 x 20 capscrew ring carrier button Page 32 ...

Page 515: ...ty Cylinder Head Assembly 1 Inlet camshaft 1 Exhaust camshaft 1 Camshaft oil seal 4 Cam cover gasket 1 Cylinder head gasket 1 Blanking plate vac spigot 1 Inlet manifold stud 2 Exhaust manifold stud 5 Inlet manifold gasket 1 Exhaust manifold gasket 1 Upper lower manifold gasket 1 Screw 5 Manifold support strut 1 Screw 1 Screw 1 Spark plug 4 Spark plug cover green 1 Modified inlet manifold upper 1 I...

Page 516: ...ntion to the crank shaft and cam positioning to avoid piston valve foul 9 Fit the new manifold support strut to the manifold and cylinder block using the new bolts supplied 10 Connect the fuel pressure regulator valve sensing hose and MAP hose to the right hand end of the intake plenum via the two spigots or single spigot and T piece 11 Fit the exhaust manifold 12 With camshaft cover removed pour ...

Page 517: ...on with the sport road spring and damper set lowered ride height specific suspension geometry with increased negative camber uprated front anti roll bar and Uniball rear toe link kit The tyres should be mounted on factory approved Elise race wheels 6J front 8J rear in order to provide good tread stability for ultimate performance Tyres Tyre designation Yokohama A038 R Size front 195 50 R15 82V K 5...

Page 518: ...rical Lightweight race battery Rear racelight conversion kit Immobiliser bridging link Sidelight switch connector bridging link Hazard switch aperture grommet Column switch aperture blanks Alloy cover for bulkhead electrics box Miscellaneous Carbon fibre seat Removable 305mm steering wheel kit Elise gear lever surround Driver only roll over bar RHD or LHD 5 point driver s harness kit Alloy fuel ta...

Page 519: ...rther 360 3 Slacken the belt tensioner clamp bolt and remove tension from the cam belt 4 Use special tool T000T1280 to hold the inlet camshaft pulley and release the retaining bolt Withdraw the pulley from the camshaft and timing belt 5 Fit the new pulley to the camshaft with the T mark just above the timing mark on the exhaust camshaft pulley and the dowel engaged in the pulley slot Use special t...

Page 520: ...ug bridging link into immobiliser connector Footwell divider alloy panel Cockpit divide switches mounting panel and strut Plug bridging link into sidelamp switch connector Gear lever handbrake shroud with trickle charger socket Fit standard Elise gear lever shroud Auxiliary power sockets mounting panel and harness Hazard switch and fit grommet Column switches and fit alloy blanks using elastomeric...

Page 521: ...tings refer to section LH Bend the float arm of the gauge sender to clear the side panel of the new tank Heater duct Remove the heater offtake duct from the radiator the heater trunking and the duct onto the footwell vents The uprated brake pads racing brake fluid and braided brake hoses are all direct replacements for the stand ard components but note that the rear hoses do not use the P clip on ...

Page 522: ... to the water rail at the front of the engine bay Route both hoses against the bulkhead outboard of the fuel filler hose and through the engine bay RH air intake aperture on some early cars it may be necessary to cut an aperture in the side closing panel Ensure that both hoses are fitted with convolute protective sleeving in vulnerable areas especially through the air intake aperture 6 Route the h...

Page 523: ... Service Notes Section XA Heat protective sieeving Oil cooler return hose Oil cooler feed hose Tie strap to water pipe Holes in rad duct inner wall 32mm diameter holes in rad duct outer wall 2000 02 Page 41 ...

Page 524: ...arness lap strap by inserting a stiff wire into the latch hole By similar technique fit the new rotary release latch to the lap strap Fit the grommet onto the new crutch strap and thread the anchor bar through the crutch strap loop Feed the strap through the seat frame cross brace aperture and the slot in the driver s seat and fit the grommet into the frame aperture Secure the crutch strap anchor ...

Page 525: ... places as shown to separate the function of the two outermost bulbs from the inner pair 2 Replace the two outermost bulbs with 3W items 3 Solder the ends of the two green cables on the new harness to the outer bulb ve tracks 4 Refit CHMSL to topshell connect conversion harness to lamp and secure to topshell and plug in to main harness 4 way connector 5 Fit bridging link into main harness sidelamp...

Page 526: ...onneau cover Fitting Procedure 1 Remove the passenger seat slide the driver s seat fully forwards and remove the cover from the rear bulkhead electronics box I 2 Remove the rear screen For race use use grommets to blank off the screen fixing holes in the bulkhead 3 If the screen is to be retained Bond an M5 x 12 big head stud A082W5128F into the two screen fixing holes in the bulkhead electronics ...

Page 527: ...nd the rest of the cockpit and mark the postions of the remaining sockets as shown in the diagram Take care when drilling the topshell to limit penetration so as not to damage any parts below e g harnesses or hoses Rivet the sockets to the body and fit the tonneau routing the drain tubes at the front beneath the instrument rail and into the passenger footwell where excess water can drain away By u...

Page 528: ...t blank off if necessary 101 Inlet Camshaft Pullev 2 5 hrs The standard engine inlet cam timing is 105 ATDC maximum opening point The modified pulley allows the inlet cam timing to be advanced by 4 to 101 MOP 1 Remove the timing belt top cover 2 Turn the engine to align the timing mark on the crankshaft front pulley with the safe position 45 ATDC mark 12 O clock on the timing belt lower cover Chec...

Page 529: ... LHD cars were factory built with oil coolers For RHD oil cooler fitting procedure see XA 17 or LSL388 Optional Not recommended for road use Delete IAC Valve 0 4 hr Remove the idle air control valve mounting bracket and plumbing Fit the blanking plugs to the inlet tract spigots on manifold underside Fit blanking grommet to backplate Saves 667g On road based cars for further performance enhancement...

Page 530: ...der to allow routing of the sensor cable 4 From the access hole in the underside of the fascia between the steering column and centre divide withdraw the harness spur with the black 12 terminal square block connector Plug in the new switch and lap sensor harness and feed through the dash hole into the column shroud area 5 Mount the push button and rotary switch to the column shroud and connect the...

Page 531: ...e Infra red sensor mounted horizontal on A post 7mm hole for push button switch 4mm slot for infra red cable 12mm hole for rotary switch Underside of instrument rail showing position of cable clips o H o c y CD a o D O CD 0 V CD O O X ...

Page 532: ...he double hoop roll over bar 2 Fitment of the new bar requires a clearance slot to be cut in the engine lid and body aperture gutter A template LSL401 for the engine lid slot is provided below to allow an initial fit to be made with initial dimensions for the body aperture measureable from this The spoiler mounting plate will also require a small clearance groove to be made to allow the backstay t...

Page 533: ...Lotus Service Notes Section XA 2000 02 Page 51 ...

Page 534: ...R A 3 Body 340R B 4 Front Suspension 340R C 8 Rear Suspension 340R D 9 Engine 340R E 9 Transmission 340R F 16 Wheels Tyres 340R G 17 Steering 340R H 18 Braking 340R J 18 Cooling 340R K 18 Fuel System 340R L 18 Electrical 340R M 19 Maintenance Lubrication 340R O 46 Heating 340R P 50 Clutch 340R Q 50 2000 02 Page 1 ...

Page 535: ...mounted on alloy side plates and a special oval section steel roll over bar Sport suspension is fitted complete with the uprated and adjustable front anti roll bar The vehicle has proven to be an extremely rare phenomenon within the motor industry as it is virtually unknown for a concept vehicle to be productionised without drastic modification The styling concepts first shown at the 1998 Internat...

Page 536: ...l The special roll over bar comprises individual hoops for driver and passenger interlinked to form a crossbraced structure fabricated from oval section steel tubing with back stays anchoring to the rear aerofoil mounting plates The composite front crash structure is revised to accommodate the new body and is supplemented by a new aluminium front undertray which incorporates longitudinal rivetted ...

Page 537: ...the front each of which is secured by four threaded fasteners The engine lid at the rear is fixed by nine threaded fasteners Sill Panels Run from behind each front wheel to sweep upwards ahead of the rear wheels Bonded to the chassis with elastomeric adhesive Side Intake Ducts Bolted to side closing panel to admit air into engine compartment Front Spoiler Splitter One piece moulding bolted to the ...

Page 538: ...otes Windscreen frame Cockpit tub Side closing panel Cockpit side screen Electronics housing Access lid Front splitter spoiler Front mudguard Rear aerofoil Rear mudguard Aerofoil support plate Rear shroud 2000 02 Page 5 ...

Page 539: ...e backstays Unplug the rear harness connector at the left hand lower corner of the engine bay 4 Release the roll over bar from the top of both chassis side rails and release both backstays from the aerofoil mounting plates Lean the roll over bar forwards to allow sufficient clearance for topshell re moval 5 Remove both outside mirrors and disconnect the side repeater lamps 6 Remove the front body ...

Page 540: ...frame 14 Protect or remove the front mudguards and the sides of the windscreen pillars from scrape damage before lifting the rear of the topshell and manoeuvring over the windscreen and off the front crash structure Fitment of Bonded Body Panels The cockpit tub windscreen frame side closing panels and cockpit side screens are bonded in that assembly order to the chassis and other panels using the ...

Page 541: ...egative camber and toe settings Ride height for both appli cations is common at 100mm front and 110mm rear with sport kit steering rack positioning plates factory fitted The standard setting for the front anti roll bar is the central of 5 available holes Geometry Ride height for geometry check front 100 mm below front end of chassis siderail 110 mm below rear end of chassis siderail 12 nominal 3 8...

Page 542: ... track use Yokohama A038 R tyres Camber Alignment 100 mm below front end of chassis siderail 110 mm below rear end of chassis siderail 2 0 0 2 0 max side side 0 2 1 5 mm toe in each side 0 2 mm 0 max side side 0 2 mm 2 7 0 2 max side side 0 2 2 5 mm toe in each side 0 2 mm 0 max side side 0 2 mm 340R E ENGINE The engine is based on the Rover 1 8 litre K series unit and is reworked in a similar way...

Page 543: ...1 oTc j l Lotus Service Notes ...

Page 544: ...sembly 4 Electronic Control Module ECM 5 Engine Coolant Temperature ECT sensor brown 6 Coolant temperature gauge sender blue 7 Oxygen sensor 8 Crankshaft position sensor 9 Manifold Air Temperature MAT sensor 10 Fuel injector 11 Fuel pressure regulator valve 12 Fuel rail ...

Page 545: ...nsor 15 Intake resonator valve 16 Ignition coil pack 17 Vehicle speed sensor 18 Vacuum reservoir 19 Manifold Air Pressure MAP sensor 20 Barometric pressure BARO sensor 21 Inertia switch 22 Resonator locking solenoid valve 23 Resonator charging solenoid valve ...

Page 546: ... read in conjunction with Service Notes manual Section EMM A limited range of trouble codes are available Trouble Code Description P0107 Manifold Absolute Pressure Circuit low input P0108 Manifold Absolute Pressure Circuit high input P0112 Intake Air Temperature Circuit low input P0113 Intake Air Temperature Circuit high input P0117 Engine Coolant Temperature Circuit low input P0118 Engine Coolant...

Page 547: ...by a vacuum actuator supplied via a pair of solenoid valves mounted on the LH side of the engine bay The solenoid valves are controlled by the engine management ECM which is programmed to close the valve when accelerating with wide throttle through the lower gears at about 30 40mph The flap capsule is connected to a vacuum charging solenoid valve which either ventilates the the capsule or connects...

Page 548: ...noid OFF To flap capsule Charging solenoid ON To flap capsule c Cruising or accelerating at 30 mph in second or third gear Both solenoids on Flap valve closed Within two seconds of condition b occuring the vacuum locking sole noid is also energised and seals the vacuum in the flap capsule This is necessary in order to prevent loss of manifold vacuum during wide throttle acceleration resulting in i...

Page 549: ...ricated from 45mm steel tube leading via a short flexible section to the standard catalytic converter and then into a new transverse stainless steel muffler with twin high level outlets The muffler is wrapped in carbon fibre faced insulation to provide heat protection Starting Procedure The fuel injection and engine management system controls fuel delivery and engine settings under all normal oper...

Page 550: ...the bar coded label fixed to the top of the clutch housing Standard C6BP Close ratio B4BP The only lubricant recommended for the Elise transmission is Texaco MTF 94 available under Lotus part number A111F6017V Gear Std Ratio Close Ratio Std Ratio Close Ratio Gear Std Ratio Close Ratio mph 1000 rpm km h 1000rpm mph 1000 rpm km h 1000rpm First 3 17 1 2 92 1 5 5 8 9 5 6 9 0 Second 1 84 1 1 75 1 9 5 1...

Page 551: ... fitment of a NEW MAGNE SIUM wheel the wheel nuts are retorqued after 25 miles driving to allow for material settlement The Yokohama A038 R tyres fitted to the Elise 340R have been jointly developed by Lotus and Yokohama specifically for Elise models and whilst the specification is optimised for track use the tyre is road legal in the U K and some European markets The tyre offers a high level of g...

Page 552: ...e radiator duct crash structure which is similar in concept but reshaped A front mounted oil cooler is an optional fit 340 L FUEL SYSTEM The fuel system is based on that of the standard Elise but the fuel tank filler spigot is angled more acutely to clear the cabin rear bulkhead New hoses connect the tank to the filler neck which uses a flush fitting lockable cap As the cap does not incorporate th...

Page 553: ...sor Automatic passive engine immobilisation to prevent the engine from being started Self powered siren to maintain protection if the vehicle battery is disconnected Dynamic coding of the transmitter keys Each time the transmitters are used the operating frequency is randomly changed to guard against the possibility of code copying Passive Immobilisation In order to provide a measure of automatic ...

Page 554: ...sing A microwave sensor is mounted in the rear bulkhead electronics compartment and is able to detect substantial physical move ment within the cockpit and trigger the alarm The range and sensitivity of the intrusion sen sor may be adjusted if necessary by turning an adjuster screw on the unit If desired the alarm may be armed with out the intrusion sensor or battery interruption ciruits being act...

Page 555: ...o check that the warning systems are operative all the tell tale lamps should light for two seconds following ignition switch on If any lamp should fail to light there is likely to be a fault on that warning circuit Seat Belt Tell Tale red As a reminder to fasten the seat belts the seat belt icon in the tachometer will flash red for about eight seconds following ignition switch on and will then be...

Page 556: ...bly caused by a hydraulic leak in one of the separate front or rear brake circuits There is a danger that air may enter the hydraulic system and cause spongey operation and extended pedal travel The split brake circuit should ensure that emergency braking will remain but the car should not be driven until the fault has been rectified Heated Windscreen Tell Tale yellow This tell tale indicates when...

Page 557: ... when the level falls to the last eighth In order to ensure the vehicle is not stranded and to protect against the potentially damaging effects of fuel starvation it is strongly recommended to refuel at the first opportunity when the display flashes Coolant Temperature Display The engine coolant temperature will be displayed at the bottom right hand corner of the panel as soon as the temperature r...

Page 558: ...third switch down in the cockpit cen tral divide functions only with ignition and when the side marker lamps have been re quested by the sidelamps switch Pressing the headlamps switch under these conditions switches on the headlamps in main beam or dip mode dependent on steering column le ver switch position Note that dip beam is provided by the projector lamp mounted in each acrylic covered front...

Page 559: ...ive at all times and when pressed flashes all the turn indicator lamps and the switch tell tale in unison This facility should be used to warn other traffic of a road hazard possibly including the prescence of the vehicle itself Use of the hazard warning lamps may be subject to local traffic laws with which drivers should familiarise themselves Column Lever Switches The steering column lever switc...

Page 560: ... 6 7 5A Direction ind 17 5A Sidelamp RH 7 10A Ignition services 18 25A Heated screen 8 7 5A Horn alarm 19 instruments 20 7 5A Dip LH 9 10A Hazard lamps 21 7 5A Dip RH 10 7 5A Horn 22 15A Main beam 11 Relays A Main beam B Sidelamps C Dip beam D Heated screen E Rad fan F Rear fog G Horn H Auxiliary J Wipe wash K Hazard flash Engine management fuses relays and diagnostic connector plug are mounted on...

Page 561: ... retain with the spring clip Connect the blue and yellow cable to the bulb terminal refit the protective cover and retain the cover with the wire spring Turn indicator lamp bulb Cover spring Protective cover Side marker lamp bulb Headlamp bulb Bulb retaining clip Note that the protective cover must also be removed for access to the headlamp alignment adjusters Side Marker Lamp Bulb Remove the prot...

Page 562: ...al box BULK 48 way circular connector Rear electrical box FTHC Fuel Tank Harness Connector Below auxiliary sockets FTU Fuel Tank Unit connector Top of tank left side CCC Centre Console Connector Behind switch panel AHC Alarm Harness Connector Behind battery OP CONN OPtion CONNector Rear electrical box FHC Front Harness Connector 1 2 Front compartment right side CHMSL HC Central High Mounted Stop L...

Page 563: ...1 Lotus Service Notes 340R A Page 29 ...

Page 564: ... BULK 45 O OW FTHC 3 C BULK 1 C BULK5 C IMHC1 INERTIA SWITCH B SPLICE E 0 2 SENSOR COIL PACK OP INJECTOR 1 NO INJECTOR 2 NG BLOC 12 BULK S oBULK 18 W INJECTOR 3 NK BUQ 13 INJECTOR 4 B l K 1 4 ULK 1 5 SEE SHEET 8 INSTR 3 A ws t FUEL PUMP SPUCEA FTHC 4 29 49 53 1 22 3 5 58 E C M sheet 2 Page 30 ...

Page 565: ...INSTR 2 FUSE A12 o FUSE B3 7 5 amp BG COOLING FAN CAVA C COOUNG FAN 6 BULK 4 SPLICE D COOUNG FAN CAVB O US CANNtSTER PURGE SOLENOID LGB NVH BUTTERFLY SOLENOID A GY BUH 23 NVH BUTTERFLY SOLENOID B GK biA 35 BULK SEE SHEET 2 A SPLICE E N SEE SHEET 4 SPLICE G 75 61 57 85 80 84 8 21 15 48 47 E C M BS RPM DROP SWITCH NOTE NOT FITTED TO STANDARD 340R sheet 3 Page 31 ...

Page 566: ...340R BULK 17 BULK 10 BULK 38 BULK 31 SPLICE G SEE SHEET 3 0 2 SENSOR SVG SPLICE M sheet 4 PWR ...

Page 567: ...Lotus Service Notes 340R WIPER MOTOR SCREENWASH PUMP B B B sheet 5 Page 33 ...

Page 568: ...H SPLICE E GWn SPLICE F GR BULK 40 i D FHC 1 CAV 1 LH LHC OCAV3 SPLICE V FHC 2 CAV 1 o O BULK 39 GW RH SIDE LIGHT CONN CAV 4 I SPLICE W 8 LH HOL HC CAV C n LH HDL HC CAV D U GW RH LIGHT CONN CAV 4 RH HDL HC CAV C RH HDL V HC CAV D r Hr 820 ohm 9 1k ohm LGK LGW OFF I I 1 1 ON i A6 7 5 A HAZARD FLASHER MODULE B a sheet 6 Page 34 ...

Page 569: ...340R i i N FUSE A18 25 amp HEATED FRONT SCREEN RELAY 1 wu WU WU INSTRUMENT CONTROLLER CAV 12 SEE SHEET 8 HEATED FRONT SCREEN B U sheet 7 ...

Page 570: ...V 15rmn m n _ 5 VOLT CAN CAN DIAL NEG DIAL POS CASE STUD 18 NU 19 GR OIL PRESSURE SWITCH 20 38 37 35 34 33 32 31 30 29 28 27 26 2 1 24 23 22 21 GW SPLICE SC2 OK SU SO SK l 4 RACE OPTION CONN CAV 4 RACE OPTION N CONN CAV 3 RACE OPTION CONN CAV 8 LAP TIME RACE OPTION CONN CAV 7 ROTARY CON 2 RACE OPTION CONN CAV 6 ROTARY CON 1 RACE OPTION CONN CAV 5 DRIVER BUTTON HIGH BEAM J FLASH FROM STALK CONI SEE...

Page 571: ... COIL 02 SENSOR FUSE B4 7 S amp NOT USED BULK S SPUCE B SEE SHEET iMM 10 IMHC 11 U o IMHC 1 B IMHC 6 B COIL I STARTEF8 SOL 1 2 3 4 IMHC 12 U o AHC 16 IMHC 5 SEE SHEET 1 SEE SHEET 1 B j M H C j 3 B IMHC 3 o AHC 15 O AHC 13 n AHC 14 W o BULK 41 LG 7 SEE SHEET 10 ALARM sheet 9 CHASSIS SPUCE M Page 37 ...

Page 572: ...UCE F RK FHC 5 C FRONT BONNET S W I T C H E S OPTIONS RU t AHC 18 c A W 19 i FUSE C1 10amp i n g k M n AHC 20 AHC 17 7 PO GW AHC 2 AHC 1 6R 1 1 1 2 1 3 1 4 1 5 1 7 1 6 1 9 18 1 10 Shc 1 12 ALARM CONTROLLER META SYSTEMS M99T2 2 1 2 17 2 10 AHC 9 O PK AHC 12 2 14 U 7 t s H h CONN 1 LEO CONN y 2 2 6 2 13 2 7 2 7 LG W K 2 1 AHC 11 U V V V V SEE SHEET 9 IMMOBILISER BY KB OPTION M23T2 MICROWAVE ft OP CO...

Page 573: ...TROLLER CAV 42 SEE SHEET 8 UO COLUMN STALK DIP BEAM RELAY a HIGH BEAM RELAY 0 VOLTS B a m uw IGH BEAM CAV 8 SEE SHEET 8 UN FimSH FUNCTION CAV 33 SEE SHEET B NU NU FUSE A2Q 7 5 amp FUSE A21 7 5 amp SPLICE H O CAVA O CAVA LH HIGH BEAMS RH CAV B U CAVB U B FHC 1 CAV 2 UY O FHC 2 CAV 2 UY O UY O CAVA UY o CAV A LH DIP BEAMS RH CAV D U CAV D U SPLICE T B sheet 11 ...

Page 574: ...340R BATTERY IGNITION UNFUSED Page 40 ...

Page 575: ...340R BATTERY SPUCE L IGNITION UNFUSED IGNITION FUSED FUSE A14 30 amp AUXILIARY SOCKET RELAY NOTE SOCKETS WILL ONLY OPERATE ABOVE 2000RPM PO PR YN AUXILIARY SOCKETS INSTRUMENT CONTROLLER CAV 27 SEE SHEET 0 sheet 13 Page 41 ...

Page 576: ...Lotus Service Notes 340R 1 i SPUCEL N FUSE A10 7 5 amp HORN RELAY P8 o HORN PUSH _ I B PY P K SPLICE C FUSE AS sheet 14 ...

Page 577: ...ET 3 SPLICE B G W FUSE A5 3 amp FUSE A3 7 5 amp FUSE A1 3 mp REAR FOG RELAY under dash RU SPLICE O BULK 44 O RH LHC 1 O LH LHC 1 RHC 6 FOGHC 1 h CHMSL1 FOG HC REVERSE LAMP FOG LAMP RH LHC 2 O LH LHC 2 CHMSL 2 U J FOG HC 4 FOG HC 2 O o sheet 15 Page 43 ...

Page 578: ...Page 44 ...

Page 579: ...O l V i 1 Lotus Service Notes n Routing In Page 45 ...

Page 580: ...or cars used on race circuits oil and filter should be changed every 3 000 miles 5 000 km For seriously raced cars oil and filter should be changed every 2 meetings The engine is factory filled with Castrol GTX 15W 50 to be used for running in until the After Sales Service At this service it is recommended to use a fully synthetic oil for optimum engine protection with the following two products b...

Page 581: ...actorily performed or the X circled if extra work and time is required The approval of the customer should be obtained before any extra work is undertaken details of which should be recorded in the space provided at the end of the schedule After Sales Service There is no charge to the vehicle owner for the labour content of the After Sales Service Only materials used will be charged Inspect means ...

Page 582: ... 12 Inspect radiator hoses pipework for damage or leaks Clean radiator finning X X X 13 Check coolant level X X X X 14 Renew coolant 12 months n WM flililiH 1 15 Inspect parking brake adjustment X X X X 16 Inspect operation of brake tell tales X X X X 17 Inspect brake pad thickness disc condition A X X X A In conditions where the brakes are sibject to heavy use inspection may be reqiired more freq...

Page 583: ...ndition of seat belt harnesses X X X 32 Top up screenwash reservoir X X X X 33 Renew alarm transmitter batteries check with customer 12 m o n t h s Road Test Performance Engine performance Tailpipe CO Clutch operation Gearbox operation Brake performance Steering performance Driveline suspension noise vibration Wheel balance General comments Additional work required Work completed by Recommended Se...

Page 584: ...nking a portion of the engine radiator outlet airflow to the vents at the front of the footwells Note that the windscreen is electrically heated see section M 34QR Q CLUTCH The clutch used on the 340R is common with the Elise but is mounted on a lightened flywheel and is balanced in unit with it Page 50 ...

Page 585: ...y EXIGE B 5 Front Suspension EXIGE C 9 Rear Suspension EXIGE D 9 Engine EXIGE E 9 Transmission EXIGE F 17 Wheels Tyres EXIGE G 18 Steering EXIGE H 19 Brakes EXIGE J 19 Cooling EXIGE K 19 Fuel System EXIGE L 19 Electrical EXIGE M 20 Maintenance Lubrication EXIGE O 41 Heating Ventilation EXIGE P 41 Clutch EXIGE Q 41 2000 03 Page 1 ...

Page 586: ... require an uncompromising machine with respon sive handling higher engine output and an elevated level of driver satisfaction with a projected use to include track days The car is fully type approved for European markets with various changes from the race cars made to improve practicality legality or user friendliness These changes include the fitment of a clear polycarbonate vented tailgate for ...

Page 587: ...mber Alignment 2000 03 Yokohama A039 195 50 R16 84V LTS 225 45 R17 90W LTS front 1 6 bar 23 lb in2 rear 1 8 bar 26 lb in2 Light alloy 12 spoke 7J x 16 ET7 8 5J x 17 ET5 80 85 Nm 59 63 Ibf ft 3761 mm 1730 mm 1201 mm excl aerial 2300 mm 1457 mm 1476 mm 155 mm 774 mm 687 mm 785 kg inc full 319 kg fuel tank 466 kg 1012 kg incl 427 kg occupants 585 kg luggage Not permissible 4 5 litre 7 9 imp pt 1 0 li...

Page 588: ... Upper and lower wishbone co axial coil spring telescopic damper 112 mm below front end of chassis siderail 122 mm below rear end of chassis siderail 2 4 0 2 max side side 0 2 1 2 mm toe in each side 0 2 mm 0 max side side 0 2 mm K16 in line 4 1796 cm3 70 71 in3 80 00 mm 3 150 in 89 30 mm 3 516 in 11 0 1 1 3 4 2 Champion RC6 6YCC 0 85 0 1 mm 0 033 in 7800 rpm Unleaded 95 RON min Multi point fully ...

Page 589: ...ducts incorporated into a spine feature A single top mounted hinge is used together with a new cable operated latch mechanism The roof panel incorporates an air intake duct for the engine bay and although retained by the same fixings as are used on the Elise hardtop the car should not be driven with the roof panel and tailgate removed Mounted on the rear body deck by two moulded plinths is a new m...

Page 590: ...anel and the bottom front edges of the clamshell wrap beneath the rear end of the sills The early type boot floor is used incorporating a rearward extension to pick up the clamshell behind the rear licence plate To remove 1 Remove both rear road wheels and wheelarch liners 2 Mark its position before releasing the tailgate panel from the hinge blade noting any shim plates Discon nect the release ca...

Page 591: ...o M6 studs moulded into the bottom of each plinth with nuts fitted inside the clamshell Loads from the aerofoil plinths are transferred into the clamshell support plates via alloy angle brackets Roof Section The roof panel incorporates an air intake duct feeding into a corresponding duct in the tailgate The single hinge for the tailgate is mounted in the rear end of the roof duct and the standard ...

Page 592: ...eaned using normal car wash preparations Aerosol type glass cleaners may be used if required but liquid or paste type abrasive polishes should N O T be used Stone Chip Protection A stone chip protective film set tailored specifically for the Exige is available under part number A111V0627S Seats Seat Belts Standard equipment consists of 111S cloth leather option trimmed seats and inertia reel seat ...

Page 593: ...pe toe links are used in conjunction with standard Elise forged steel hub carriers The specified mid laden ride height of 112 122 mm differs from other sport variants due to the increased wheel diameter For optimum rear bump steer set up information refer to sub section XA 8 Geometry Mid laden ride height for geometry check front rear Camber Alignment 112 mm below front end of chassis siderail 122...

Page 594: ...WSi 1 Lotus Service Notes age 10 ...

Page 595: ...embly 3 Electronic Control Module ECM 4 Engine Coolant Temperature ECT sensor brown 5 Coolant temperature gauge sender blue 6 Oxygen sensor 7 Crankshaft position sensor 8 Manifold Air Temperature MAT sensor 9 Fuel injector 10 Engine management vehicle speed sensor 11 Fuel pressure regulator valve 12 Fuel rail ...

Page 596: ... Intake resonator valve 16 Ignition coil pack 17 Speedometer sensor 18 Fuel filter 19 Inertia switch 20 Barometric pressure BARO sensor 21 Manifold Air Pressure MAP sensor 22 Resonator charging solenoid valve 23 Resonator locking solenoid valve 24 Vacuum reservoir ...

Page 597: ...he cabin rear bulkhead For fault diagnosis the Tech 1 tool including the Esprit V8 cartridge should be plugged into this socket and any trouble codes read in conjunction with Service Notes manual Section EMM A limited range of trouble codes are available Trouble Code Description P0107 Manifold Absolute Pressure Circu t low input P0108 Manifold Absolute Pressure Circu t high input P0112 Intake Air ...

Page 598: ...and is designed to suppress resonant intake noise under certain engine operating conditions The valve is sprung open and is closed by a vacuum actuator supplied via a pair of solenoid valves mounted at the LH side of the engine bay The solenoid valves are controlled by the engine management ECM which is programmed to close the butterfly valve when accelerating with wide throttle through the lower ...

Page 599: ...Locking solenoid OFF Charging solenoid ON Manifold vacuum To flap capsule c Cruising or accelerating at 30 mph in second or third gear Both solenoids on Flap valve closed Within two seconds of condition b occuring the vacuum locking sole noid is also energised and seals the vacuum in the flap capsule This is necessary in order to prevent loss of manifold vacuum during wide throttle acceleration re...

Page 600: ...duct or airbox with dirt Follow the filter manufacturer s cleaning instructions 1 Dislodge any large embedded dirt by tapping the filter gently Brush with a soft bristle brush to remove other dirt 2 Spray Pipercross foam air filter cleaner liberally onto the entire filter Let soak for 10 minutes 3 Never use other cleaning agents e g gasoline caustic strong detergents or solvents Never use steam cl...

Page 601: ...ing pres sure to position III to engage the starter motor As soon as the engine starts release key pressure and adjust the accelerator position to maintain 2 000 rpm for 10 seconds to minimise emissions iv If the engine fails to start within 15 seconds stop cranking and pause for 10 seconds before a second attempt If further efforts are unsuccessful increase throttle opening to halfway and repeat ...

Page 602: ...raised and fifth is lowered Compared with the 111S the overall ratios are raised slightly due to the larger diameter wheels used on the Exige The only lubricant recommended for the Exige transmission is Texaco M T F 94 available under Lotus part number A111F6017V Gear Ratio Final Drive mph km h 1000 rpm First 2 92 1 5 8 9 3 Second 1 75 1 9 9 15 9 Third 1 31 1 4 20 1 13 1 21 1 Fourth 1 03 1 16 7 26...

Page 603: ...ad 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 Note that the Exige wheel tyre assemblies are not approved for fitment on other Elise variants Note that the wheelnuts and roadwheels on the Exige use a 60 taper and not the spherical seating ...

Page 604: ...and XA EXIGE J BRAKE The Exige uses the drilled cast iron discs and brake pads as fitted to the Elise 111S For track use the motorsport brake pads front A111J0150S rear A111J0151S are recommended For further information refer to section JH EXIGE K C Q O U N G The engine cooling system is unchanged from standard but all Exige models are factory fitted with oil coolers EXIGE L FUEL SYSTEM The fuel s...

Page 605: ...e immobiliser tell tale mounted ahead of the gear lever blinking once every two seconds To mobilise the engine press once the button on the transmitter key head with ignition either on or off Mobilisation will be acknowledged by the tell tale being extinguished Upgraded Security System For enhanced protection from theft and vandal damage the EXIGE may be specified factory built with a Meta vehicle...

Page 606: ...sequence for about ten cycles To silence the alarm when triggered disarm as described below Disarming the Alarm To disarm the alarm prior to entering the vehicle or if the alarm has been triggered press once the button on the transmitter key This command will be acknowledged by One flash of the hazard warning lamps Extinguishing of the alarm tell tale ahead of the gear lever If the alarm had been ...

Page 607: ... battery ensure that the alarm system is disarmed On reconnection of the battery the alarm will automatically be set Have the transmitter ready to disarm Component Location The alarm system components are located as follows Electronic Controller Mounted on the top of the scuttle beam above the passenger footwell Some accessibility is available via the audio set aperture Siren Unit Mounted on the p...

Page 608: ...g kit comprises a pair of speakers mounted in the rear bulkhead and wired to a 16 pin ISO connector behind the fascia Cars built without this option retain the speaker wiring but have blanking panels in place of speakers Due to packaging restraints Exige speakers are smaller than those in the Elise and are common with Esprit fascia speakers with 100mm diameter SOW peak 15W RMS 2000 03 Page 23 ...

Page 609: ... 2A Alarm ignition 3 20A Interior fan 4 15A Wiper motor 5 3A Reverse lamp 6 7 5A Direction ind 7 10A Ignition services 8 7 5A Stop lamps battery services 9 10A Hazard lamps 10 7 5A Horn 11 10A Alarm Int lamp Relays A Horn B Cooling fan C D Slot 12 13 14 15 16 17 18 19 20 21 22 Rating Circuit 25A Cooling fan 20A Audio 20A Cigar lighter 5A 5A Dip beam Main beam Sidelamp LH Sidelamp RH 20A Fast fan s...

Page 610: ...management OBD Engine man canister purge idle control Ignition coil Alarm microwave sensor Alarm system immobiliser m23 Fuel pump Injectors Starter solenoid Engine management controller OBD2 connector Engine management ignition supply me arnes rmr 2000 0 3 Page 25 ...

Page 611: ...ay circular connector F T H C Fuel Tank Harness Connector F T U Fuel Tank Unit connector A H C Alarm Harness Connector O P C O N N OPtion CONNector F H C Front Harness Connector 1 2 C H M S L H C Central High Mounted Stop Lamp Ham Conn F O G HC F O G lamp Harness Connector HDL HC HeaDLamp Harness Connector R H C Rear Harness Connector Exige Sheet 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Location Rear e...

Page 612: ...Lotus Service Notes Exige 2 0 0 0 0 3 Page 27 ...

Page 613: ...Lotus Service Notes Exige Page 28 2000 03 ...

Page 614: ...TR PACK V FUSE AH EE3 FUSE 837 5 a n p COOUNG FAN RELAY BN LA C V A B 1 SI BG COOUNGFAN CAVA C J COOUNG FAN O SPLICED BULK4 COOUNGFAN CAV B U US CANMSTER PURGE SOLENOK LGB NVH BUTTERFLY SOLEMMDA GY B u f r 23 NVH BUTTERFLY SOLENOIDB OK BULK U eJLiK 9 02 SENSOR 3 1 2 4 SEE SHEET 2 t SPLICE E N ft SEE SHEET 4 SPLICE G BULK 6 u MBULK t n BULK 7 57 85 80 4 21 IS 48 E C M sheet 3 9nnn n7 Page 29 ...

Page 615: ... A B CRANK SENSOR TWISTED PAIR BULK a 47 BULK 21 A B C U V BULK 20 U W w 47Kohms BULK1S U SPUCEC THROTTLE POSITION 1 2 3 w BAROMETRIC A B C SPLICE B U o BULK 42 BULK 3 u LGO BULK 22 O BULK 2 O 72 4 87 St 73 79 11 75 9 NOTE RESISTOR IS APPROXIMATELY 50mm BACK FROM ECU CONNECTOR 7 87 37 88 38 35 39 55 E C M 27 28 BULK 17 BULK 10 V BULK 38 BULK 31 SIG SPUCEM sheet 4 SPLICE G SEE SHEET 3 02 SENSOR Pag...

Page 616: ...Lotus Service Notes Exige 2000 03 Page 31 ...

Page 617: ...Lotus Service Notes Exige Page 32 2000 03 ...

Page 618: ...Lotus Service Notes Exige 2000 03 Page 33 ...

Page 619: ...Lotus Service Notes Exige Page 34 2000 03 ...

Page 620: ... SPUCEE ION COM 02SEN30R I FUSE 84 7 5 amp NOT USED BULK 9 SPUCE SEE SHEET IMH io IMHC 11 I I IMHC 1 bI IMHC IB T o t T i J f STARTER SOL IMHC 12 2 _3 4 o AHC 11 IMHC 6 r i SEE SHEET 1 SEE SHEET 1 i B JMHC _ IMHC 3 _ 3 B o ft I_AHC1S A AHC 13 o AHC 14 W LG O BULK 41 7 SEE SHEET 10 ALARM sheet 9 CHASSIS SPLICE M 2 0 0 0 0 3 Page 35 ...

Page 621: ...Lotus Service Notes Exige Page 36 2000 03 ...

Page 622: ... SEE SHEET 19 REAR FOG A RG 1 FUSE A1S I I RB FUSE16 Samp SPLICE K RO RO ft BULK 33 SEE SHEETS MSTRUPACX SEE SHEET 13 CIGAR LIGHTER BULK RB N FHC CAV 8 RO I SPUCE L RH HDL HC CAV B RO RHLAMP CAV 3 RH SIDE LIGHT CONN CAV 3 i RB O CHMSL HC CAV 4 FHC CAV 4 ft RH HDL HC V CAVO RHLAMI CAV 1 U O LH LHC CAV 3 LHLH CAV1I S NUMBER PLATE LAMPS CHMSL HC CAV 1 Y O 1 sheet 12 SPLICE A 2000 03 Page 37 ...

Page 623: ...Lotus Service Notes Exige Page 38 2000 03 ...

Page 624: ...A Lotus Service Notes Exige 2000 03 Page 39 ...

Page 625: ...Lotus Service Notes Exige Page 40 2000 03 ...

Page 626: ...e and Elise 111S models is 9 000 miles 15 000 km For 340R Sport 160 and Exige models the interval is 6 000 miles 10 000 km Maintenance Schedule LSL348 has been updated to f D level to include the Exige VENTILATION As standard Elise As standard Elise 2000 03 Page 41 ...

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