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Lotus Evora, Service Notes

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Lotus Evora Service Notes Download Page 192

Page 10

 

 

Lotus Service Notes   

 

 

    Section JL

4.  Release the two nuts securing the master cylinder to the brake servo and remove the cylinder.

 

5.  Refit the master cylinder in reverse order to removal, using new locknuts and tightening to the following 

torques:

 

- Master cylinder fixing nuts; 25 Nm

 

- Brake pipes to cylinder; 16 Nm

6.  Fill the reservoir with DOT 4 non-mineral type brake fluid, and bleed the complete brake system of air 

using the procedure in Sub-section JL.3.

JL.9 - VACUUM SERVO UNIT

The vacuum brake servo is secured to the front face of the pedal box via a machined alloy spacer, and is 

operationally interposed between the brake pedal and master cylinder.  Engine generated vacuum is used to 

provide pneumatic assistance to the effort applied at the pedal.  The unit is supplied by Continental Teves and 

is a dual diaphragm unit combining a 178mm (7 in) and 203mm (8 in) diameter vacuum chamber into a single 

compact unit to provide a 5:1 assistance ratio.  With the exception of the air filter and vacuum elbow/non return 

valve, the unit is a non-servicable sealed unit which if found to be faulty, must be replaced as an assembly.  

The air filter (surrounds the input push rod) should be replaced whenever the brake system is overhauled, and 

cleaned or replaced more frequently if the vehicle is operated in dusty conditions.  A non-return valve is incor-

porated into the vacuum hose elbow connector in the front case of the servo unit.  The elbow connector valve 

is a push fit into a grommet in the servo shell, and is supplied complete with the grommet.

The servo is of the ‘suspended in vacuum’ type, wherein two flexible diaphragms divide each of two sec-

tions within the steel shell into two chambers.  One pair of chambers, towards the front side of each diaphragm, 

is connected via a non-return valve, to the vacuum produced in the engine’s inlet plenum chamber.  The second 

pair of chambers, towards the rear side of each diaphragm, connect either to the front chambers, or to atmos-

phere, under the control of a double acting face valve.

Brakes Off

When the brake pedal is released, the diaphragms and driving piston are pushed fully rearwards by the 

main spring, and the input rod (connected to the brake pedal) is also pushed rearwards by its own spring, caus-

ing the face valve to close the atmospheric connection.  Engine vacuum admitted to front of the diaphragms is 

also communicated to rear of the diaphragms via the face valve.  The unit is in stable equilibrium.

Initial Movement

Initial movement of the brake pedal causes the input rod, input piston and face valve to move forwards, 

closing off the front/rear communication. 

Pressure Balance

Further pressure on the brake pedal pushes the input piston further forwards and opens the face valve to 

bleed atmospheric pressure into the rear chambers.  The resultant pressure imbalance across the diaphragms 

acts to apply a force to the driving piston to assist pedal effort.  When the combined input force from foot pressure 

and servo pneaumatic pressure balances the reaction force of the main spring and master cylinder, movement 

of the driving piston ceases, and both face valve ports close.  The system is once again in equilibrium.

Summary of Contents for Evora

Page 1: ...SERVICE NOTES Lotus Cars Ltd Hethel Norwich Norfolk NR14 8EZ England Tel 44 0 1953 608000 Fax 44 0 1953 608300 www LotusCars co uk Part number B132T0327D 09 01 Lotus Cars Ltd 2009 ...

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

Page 3: ... Engine Management Lotus supplement EJ Toyota engine repair manual Engine Management EMR Transmission Lotus supplement FL Toyota transmission manual Wheels Tyres GJ Steering HI Brakes JL Engine Cooling KJ Fuel System LN Electrics MR Maintenance Lubrication OK Air Conditioning Heating Ventilation PN Clutch QJ Interior Trim VE Passive Restraint WF see separate CD T000T1516F see separate CD T000T1517...

Page 4: ...gine undertray The number is repeated on a bar code label applied to the front face of the left hand cylinder head which may be viewed from above using a mirror The full V I N should always be quoted with any vehicle enquiries together with the engine number if the query is engine related Factory records are filed against V I N and specification change points are identified by V I N or engine numb...

Page 5: ...Page 5 Lotus Service Notes Introduction MODEL HISTORY Evora Introduction First deliveries commence June 2009 at 09 VIN serial number 0721 ...

Page 6: ...ntified by a blue sticker Beneath each end of the fuel tank bay rear crossmember just ahead of the front edge of the engine bay undertray If using a single jack for wheel changing purposes a single rear lifting point B may be used to raise both wheels on that side of the car With the limited vision available under these circumstances extra care must be taken to position the jack correctly Note tha...

Page 7: ...Page 1 Lotus Service Notes Section AJ CHASSIS SECTION AJ Sub Section Page General Description AJ 1 3 Chassis Straightness Check AJ 2 4 Rear Subframe AJ 3 5 Front Subframe AJ 4 6 ...

Page 8: ...AIN CHASSIS TUB Mounting face for rear subframe Upper gusset Main siderail Gusset panel Scuttle beam Pedal box apeture Seat mounting crossmember Steering column Hinge post cut out reinforcement Mounting face for Door hinge post front subframe a31 ...

Page 9: ... Note that this closing panel contributes to the structural integrity of the chassis such that the vehicle should not be operated without it properly fitted The front scuttle structure comprises a scuttle beam the two door hinge posts and the foowells A verti cal extrusion is used to form each door hinge post which is secured to the end of the scuttle beam and by a rearwards leading tapering chann...

Page 10: ...round plane e g an accurately set and maintained suspension geometry ramp lift Position the car on the lift and proceed as follows 1 Identify the tooling indents in the lower surface of each chassis main side rail At the front end just behind the front crossmember and at the rear just ahead of the fuel tank bay rear crossmember Note that three of the machined oval areas are drilled but not at the ...

Page 11: ...gressively and evenly removing the seven fixing bolts from each side of the frame At each side Two bolts from beneath into threaded inserts in the chassis rail lower surface Three bolts into captive nuts in the chassis rail side face Two bolts from within the engine bay using loose nuts ahead of the siderail closing plate 4 Withdraw the subframe taking note of the shim plates fitted at each side b...

Page 12: ...ing the front subframe it is recommended to remove all front bodywork the front suspension assembly and the HVAC equipment in order to allow easier handling of the subframe and to minimise potential component damage 1 Remove the front clamshell A panels and front bumper 2 Recover the a c refrigerant and drain the engine cooling radiator Remove the HVAC unit see section PN and disconnect all hoses ...

Page 13: ...Page 7 Lotus Service Notes Section AJ ...

Page 14: ...neral Description BU 1 3 Lotus Composite Body Features BU 2 3 Bodycare BU 3 4 Accident Damage Assessment BU 4 5 Body Panel Bonding Materials BU 5 6 Replacement of Bonded On Panels General BU 6 9 Roof Panel BU 7 9 Windscreen Frame BU 8 10 Body Side Panels BU 9 11 Rear Bulkhead BU 10 12 ...

Page 15: ... Windscreen frame Roof panel Rear bulkhead Ventilation panel Tailgate Reservoir access hatch Rear spoiler Front bumper A panel Door Body side panel Rear clamshell Rear bumper denotes panels bonded with elastomeric adhesive b357 Evora Composite Body Panels ...

Page 16: ...A steel panel similarly treated would become dented or deformed The cracking may be confined to the surface layer with no reduction in panel strength but if the damage is more severe the composite structure below the surface may be weakened Localised repairs can be made in either case Possible causes of surface cracking include Vehicle collision Inappropriately sitting leaning heavily or pushing o...

Page 17: ... However car finishes are not immune to damage and amongst the more common causes of deterioration are Atmospheric contaminants dust soot ash and acidic or alkaline aerosol mist can chemically attack paint Abrasion blowing sand and dust or a dirty washing cloth Tree sap and insect fluids can form a water insoluble polymer that adheres to the paint Bird excrement highly acidic or alkaline they can ...

Page 18: ...e outside on a hard standing or under a carport is to be preferred BU 4 ACCIDENT DAMAGE ASSESSMENT The repair method to be employed in the rectification of accident damage to composite panels is to be assessed reletive to the particular panel and its method of attachment Bolt on Panels Front Clamshell Reservoir Hatch Front Bumper A Panels Door Shells Rear Clamshell Rear Bumper Tailgate Ventilation...

Page 19: ...s part no A082B6281F Zinc plated and passivated steel Cleaner Betaclean 3900 Lotus part no A100B6008V Primer Betaprime 1707 A B Lotus part no A111B6374V Adhesive Betaseal 1701 Lotus part no A082B6281F Glass Cleaner Betabrade F1 Lotus part no A120B6043V or Betaclean 3300 Lotus part no A120B6042V or Betaclean 3900 Lotus part no A100B6008V Primer Betaprime 5500 Lotus part no A120B6041V Adhesive Betas...

Page 20: ...l beads of material approx 3mm dia x 50mm to the ceramic sur face of the glass Use a fibre free cloth to thoroughly clean the ceramic surface of the glass to be bonded and then wipe off all residual amounts A wipe on wipe off process ii Fibre free cloth Apply material to the fibre free cloth and thoroughly clean the ceramic surface of the glass to be bonded and then wipe off all residual amounts A...

Page 21: ...o dry for a minimum of 15 minutes before applying adhesive If adhesive is not applied with 24 hours re activate by applying a further coat of Betaprime 5404 Notes The appearance of the primed areas should be deep black in colour with no streaks or voids To achieve this appearance apply in smooth continuous uni directional movement not short backward and forward movements The latter technique resul...

Page 22: ...nsing Betaseal 1701 adhesive may be obtained directly from PC Cox Ltd Turnpike Lane Newbury Berks RG14 2LR Tel 44 0 1635 264500 With some panels it may not be practicable to attempt to removal intact for later refitment damage to the bonding flange is likely to occur Consequently when expedient the panel can be cut away for better access to the bonded joint It is not necessary to remove all traces...

Page 23: ...the front section of both body sides be released from the chassis The elastomeric adhesive bonding the frame to the scuttle and other body panels requires cutting with a reciprocating knife if necessary cutting the frame itself to allow improved access to the joint It is unlikely to be economic to attempt to remove a windscreen frame for re fitment To replace windscreen frame 1 Remove the front cl...

Page 24: ...head panel and roof The sill bottom flange is bonded into a groove in the chassis main side rail and it is necessary to cut the panel to effect its removal it is not practical to attempt to remove a body side panel intact for later refitment If damage occurs to the panel which is not repairable in situ the body side panel should be renewed However in view of the extensive amount of labour required...

Page 25: ...ded to the rear side of the panel The cabin rear window is bonded directly to the bulkhead using the same materials and procedure as is used for the windscreen A screw fixed panel is provided on the right hand side to allow access from the cabin to the alternator compressor and adjacent engine components Replacement of the complete bulkhead panel is unlikely to be required without a complete body ...

Page 26: ...with Betawipe VP 04604 yellow cap and prime with Betaprime 5404 red cap or with Betawipe 4000 to re activate old adhesive Apply a bead of Betaseal 1701 to the bonding path on the chassis and fit the bulkhead frame assembly into position by securing the frame with its four bolts to the extruded brackets which form part of the chassis tub If necessary apply additional adhesive into the joint and use...

Page 27: ...t Clamshell BV 4 5 Front Bumper BV 5 5 Rear Clamshell BV 6 6 Rear Bumper BV 7 8 Door Mirrors BV 8 9 Door Shell Beam Hinges BV 9 10 Door Weatherstrip Seals BV 10 11 Door Window Guide Rails Lift Mechanism BV 11 12 Door Latch Mechanism BV 12 14 Windscreen Removal Replacement BV 13 15 Tailgate Glass BV 14 17 Cabin Rear Window BV 15 18 Rear Quarter Light Window BV 16 18 ...

Page 28: ...creen frame Roof panel Rear bulkhead Ventilation panel Tailgate Reservoir access hatch Rear spoiler Front bumper A panel Door Body side panel Rear clamshell Rear bumper Front subframe Main chassis tub Rear subframe GENERAL OVERVIEW Seat belt mounting frame b357 ...

Page 29: ... rear bulkhead to which the hinge stators are secured with two M8 screws The steel hinge pin is an interference fit into the stator and supports two top hat synthetic bushes pressed into the bore of the hinge rotor with an E clip used for retention Oversize hinge fixing holes allow for the adjustment of tailgate panel shutlines Pivot ball pins for the twin gas struts are screwed into captive nuts ...

Page 30: ...e front wheelarch and the door aperture with each panel screw fixed to the front clamshell and body sill A panel removal replacement 1 Slacken or remove the front wheelarch liner and release the two screws securing the A panel to the rear lower flange of the front clamshell 2 Slacken or remove the two screws securing the bottom edge of the panel to the body sill and withdraw the panel 3 Replace in...

Page 31: ...w the headlamp 4 From within the front of each wheelarch release the three fixings securing the clamshell to the top edge of the bumper 5 From within the back of each wheelarch release the two fixings securing the clamshell to the top of the A panel and the single screw to the chassis bracket Disconnect the side repeater lamp 6 From the headlamp apertures release the two nuts at each side securing...

Page 32: ...re replacing the bumper in reverse order to removal inserting the top flange between the clamshell and support rail BV 6 rear clamshell The rear clamshell comprises the principal body moulding aft of the doors and includes the integral boot box The separate rear bumper panel is screw fixed to the rear face of the clamshell The front of the clamshell is secured to the body side mouldings and the ba...

Page 33: ...ry cover battery and tray and feed the two battery cables out through the clam shell grommets 5 Boot box From inside the boot release the 8 fixings securing the boot floor to the subframe and the 4 fixings in the boot front wall securing the heatshield Release the single screw securing the header tank bracket to the boot wall 6 Wheelarch From within the front of each rear wheelarch release the fix...

Page 34: ...ule and tyre pressure monitoring harnesses and feed through the clamshell 11 Carefully lift the clamshell from the body and lay aside on a protected surface Note and retain any shim washers or plates used at each fixing point 12 Refit the clamshell in reverse order to removal taking appropriate precautions to protect surfaces from damage during the installation process Refit any shim washers or pl...

Page 35: ...m period of 10 minutes An optional specification includes an electric fold facility for use when parking or negotiating narrow gaps Each mirror comprises a cast alloy bracket carrying a black textured plastic housing and a gimbal mounted glass carrier driven by a pair of electric motors and to which is attached the mirror glass A third motor provides the fold function A sprung attachment of the mi...

Page 36: ... cavity before using a suitable terminal extractor tool to depress the retain ing barb and withdraw each terminal from the connector Remove the three screws around the pivot mechanism and withdraw the mirror from the plinth Note that the plinth upper finisher is heat bonded to the plinth If necessary new parts can be mated using a soldering iron or similar to secure 7 New mirror assemblies may be ...

Page 37: ...oor drop glass uses flocked EPDM wipe seals on the inner and outer top edges of the door shell to minimise water ingress into the door Each main length of seal is bonded to an aluminium U section barbed carrier which is pressed on to the appropriate door top flange These two seals are linked around the back of the door shell glass slot by an integrated moulded capping section secured to the door b...

Page 38: ... the glass The lower end of each of the guide rails is adjustable in out via a screw mechanism to enable the correct weatherstrip seal loading to be achieved whilst the glass upward travel is limited by an adjustable stop on the lift mechanism The lift mechanism uses a top hat section steel lift channel curved to match the window guide rails and attached to the door shell An alloy carriage plate c...

Page 39: ...r glass waist seal see sub section BV 10 3 Release the two clamps securing the glass to the lift channel and slide the glass out of the door 4 New door glasses are supplied with the slider blocks pre fitted If a slider block should become detached the old adhesive should be cleaned off the bonding surfaces cleaned with Betaclean 3900 A100B6008V and the following products used to rebond the slider ...

Page 40: ...cit interference with the locking system Normal operation of the locking functions is performed electronically via the transmitter fob see Section MR but if necessary the doors can be locked mechanically The LH door can be locked by using the key in the exterior lock barrel Both doors can also be locked individually by lifting the exterior release handle with door open pressing down the door sill ...

Page 41: ...ement The Evora windscreen is constructed from two layers of glass the inside component of which is green tinted sandwiching a synthetic solar reflecting interlay to form a 5mm thick laminate A black ceramic obscura tion band with graduated fade out is applied to the inner surface periphery The windscreen is bonded to the composite body frame using an elastomeric polyurethane adhesive and contribu...

Page 42: ...glass following the supplier s directions Position the plinth centrally and with the bottom closed end 7mm from the bottom edge of the obscuration patch 8 Prime the bonding area on the glass to a width of 25mm with Betaprime 5500 green cap A120B6041V avoiding the VIN window Allow the primer fully to dry 9 Fit the new self adhesive filler strip A132U0266F to the inside top edge of the glass and the...

Page 43: ...nto unprimed glass can be readily peeled off after it has cured b Any spillage onto the bldy can be removed with either Wipe Cleaner No 4 or white spirit Shelf life a Betaseal primer has a useful life of about 24 hrs after exposure to the air after which it starts to become spongy If the material is spongy DO NOT USE Always use glass primer immediately on opening and replace the lid after use b Be...

Page 44: ...tally and use duct tape to hold the glass in position until the Betaseal is fully cured This will take approximately 4 hours dependent on atmospheric conditions with a longer period required in dry atmospheres Reconnect the HRS cables Refer to sub section BV 13 for spillage of material and shelf life advice BV 15 CABIN REAR Window The cabin rear window is a double glazed unit to enhance insulation...

Page 45: ...hown in sub section BV 13 and holding the cartridge vertically extrude a bead of adhesive around the glass periphery Manipulate the two ends of the bead together to form an unbroken ring 12 As shown in the illustration insert into the top run of adhesive two 5mm spacer blocks A124U0069F and into the bottom run two 4mm spacers A075U0588F 13 Using a suction cup carefully position the glass onto its ...

Page 46: ... CK FRONT SUSPENSION SECTION CK Sub Section Page General Description CK 1 3 Geometry Adjustments CK 2 3 Wishbone Pivot Bushes Swivel Joints CK 3 6 Anti Roll Bar CK 4 7 Suspension Disassembly Assembly CK 5 8 Front Wheel Bearings CK 6 10 ...

Page 47: ...amper mounting bracket Top wishbone Upper steering swivel joint Anti roll bar Hub carrier Spring damper Steering arm unit Track rod end ball joint Bottom wishbone Hub bearing unit Anti roll bar drop link Lower steering swivel joint Brake calliper lower boss c49 ...

Page 48: ... ride refinement The dual rate coil spring is mounted with the close coiled end lowermost A 28mm o d tubular steel anti roll bar is mounted in rubber bushes to the underside of the subframe and projects through the lower wishbone before connecting to the wishbone rear leg via a short ball jointed drop link and a forged steel bracket The hub bearing unit which is common to all four wheels is fixed ...

Page 49: ...e rack tie rods into or out of the track rods In order to preserve the required bump steer characteristic and steering symmetry the effective length of each track rod must remain equal adjust each tie rod by a similar amount Hold the track rod using the flats provided and slacken the locknut Repeat for the opposite side Turn each tie rod a similar amount As a guide turning both tie rods by one qua...

Page 50: ...ained by vertical guides integral with the subframe structure whereas the pivot bolt hole in the subframe is slotted horizontally Thus by turning the bolt and eccentric cams the wishbone pivot point may be moved inboard or outboard When adjusting camber the front and rear pivot bolts should be moved by a similar horizontal distance to minimise the effect on castor see below but be aware that the h...

Page 51: ...e rear pivot point movement After adjustment ensure that the nuts are tightened to 86 Nm only at ride height CK 3 wishbone pivot bushes swivel joints Pivot Bushes The upper and lower wishbone pivot bushes are bonded rubber type with a plastic flanged outer sleeve an alloy inner sleeve and an aluminium interleaf sleeve within the rubber bush to control the flexing character istic The rubber materia...

Page 52: ...may be replaced using suitable press tools CK 4 ANTI ROLL BAR The tubular steel anti roll bar is mounted beneath the front subframe in rubber bushes retained by extruded alloy clamps One clamp secures the bar at each side to a bolt fixed alloy extrusion bridging the chassis drop towers for the lower wishbone front and rear pivots Each end of the bar loops upwards through the lower wishbone and use...

Page 53: ...emove the complete assembly of spring damper top mounting bracket from the car in order that spring compression may be carried out in the safest manner Remove the 4 bolts securing the top mounting bracket to the subframe and the single bolt securing the lower end of the damper to the bottom wishbone bracket Withdraw the assembly to a workbench 9 Using spring compressor clamps and taking all suitab...

Page 54: ...ower seat Use the middle position for standard ride height setting Use spring compressor clamps to assemble the spring damper top mounting bracket spring close coils lowermost before fitting the complete assembly to the car Do not omit the spring top seat cushion Pump the brake pedal to reposition the pads before driving the car The Service Schedule specifies that the security of the front and rea...

Page 55: ... If there is found to be any discernible free play in the hub bearing or any roughness or tight spots can be felt or any untoward noise heard or any signs of lubricant expulsion are evident the hub assembly should be replaced there is no provision for adjustment or replacement of individual bearings To Replace Hub Bearing Assembly 1 With the wheel removed release the two fixing bolts and remove th...

Page 56: ... DJ REAR SUSPENSION SECTION DJ Sub Section Page General Description DJ 1 3 Geometry Adjustments DJ 2 3 Wishbone Pivot Bushes Spherical Joints DJ 3 6 Anti Roll Bar DJ 4 6 Suspension Disassembly Assembly DJ 5 7 Rear Wheel Bearings DJ 6 9 ...

Page 57: ...ear Suspension Layout Spherical joint Spring damper unit Top wishbone Damper top mounting bracket Calliper mounting ARB Turnbuckle lug drop link Anti roll bar Lower wishbone Toe control link ARB chassis Hub unit mounting bush Hub carrier d51 ...

Page 58: ...top eye for noise suppression and a through bolted spherical steel joint in the lower eye for optimum dynamic response and is orientated with the damper rod uppermost The dual rate concentric coil spring abuts against a lower seat fixed to the damper body and an upper seat secured to the damper top eye but also bolted to the subframe thus relieving the damper top bush of vehicle weight to the bene...

Page 59: ...imilar Any bars used must be longer than the length of the car and be suitably stiff and straight Set up the bars or elastic on each side of the car at wheel centre height as shown an the diagram so that A A B B and C C Measure the distance from the bar to the rim of the wheel concerned at the front and rear of the centre line of the wheel D1 D2 If the front dimension D1 is greater than the rear d...

Page 60: ... of camber adjust ment The pivot bolt is inserted from the rear with the bolt head featuring an integral eccentric cam and with a corresponding eccentric camplate clamped beneath the nut on the front side of the rear pivot The camplate is keyed to the bolt via a tongue and groove feature to ensure alignment between the two cams Each cam is constrained by vertical guides in a riveted insert in the ...

Page 61: ... sleeve and an alloy inner sleeve The bush may be replaced using suitable press tools Spherical Joints Through bolted spherical joints are used at the outboard ends of the upper and lower wishbones both ends of the toe control links and in the lower eye of the dampers All joints have an outside diameter of 40mm apart from the lower wishbone joint pressed into the hub carrier which is 47mm Spherica...

Page 62: ...t the parking brake is released back off the brake shoe adjuster remove the two countersunk retaining screws and withdraw the brake disc drum from the hub 4 Release the single screw securing the wheel speed sensor and withdraw the sensor from the hub car rier 5 Release the four hex head securing bolts and withdraw the hub unit from the hub carrier and driveshaft Note that this unit is common to al...

Page 63: ...tive nuts with no secondary locking mechanism apply a suitable thread locking compound If separate self locking nuts are used assess the locking torque and renew the nuts in any case of doubt The ARB drop link ball pin self locking nuts should always be renewed Take care to match mark and refit the eccentric cam adjusters on the lower wishbone rear pivot to facilitate subsequent geometry checking ...

Page 64: ...NGS The hub bearing unit which is common to all four wheels is fixed to the hub carrier by 4 hex head bolts and incorporates a double row ball bearing with the inner race of the outboard bearing formed directly in the hub forging and the inner race of the inboard bearing retained by a swaging operation on the hub flange Inboard and outboard grease seals are included in the assembly with a 48 pole ...

Page 65: ...f the brake shoe adjuster remove the two countersunk retaining screws and withdraw the brake disc drum from the hub 3 Using a Torx socket release the four bolts securing the hub bearing unit to the hub carrier and with draw 4 Fit the new hub bearing unit to the hub carrier and driveshaft apply Permabond A130 A912E7033 to the threads and retain the unit with the four Torx bolts tightened to 70 Nm 5...

Page 66: ...TION EJ Sub Section Page Introduction EJ 1 3 Air Cleaner Element Inspection Replacement EJ 2 3 Engine Oil Filter Change EJ 3 4 Auxiliary Drive Belt EJ 4 5 Engine Removal Replacement EJ 5 5 Engine Special Tools EJ 6 7 Engine Repair CD T000T1506 EJ 7 7 ...

Page 67: ...e ol functions achieve improved engine performance fuel economy and reduced exhaust emissions 01MEG11Y 285EG01 mproved eng EJ 1 INTRODUCTION General Layout Throttle body Variable Valve Timing VVT sprocket hub Coolant outlet housing Water pump Oil pump Oil filter Acoustic Control Induction System ACIS butterfly valve Hydraulic tappet finger post Primary catalytic converter Cross bolted main bearing...

Page 68: ...hrottle Control System intelligent to facilitate traction control skid control and cruise control AICS Air Intake Control System to reduce intake noise in the low to mid range of engine speed without sacrificing efficiency at high engine speed The engine management system is programmed by Lotus using the T4e controller The engine is mated to a type EA60 6 speed manual transmission supplied by Toyo...

Page 69: ...Take care not to overfill Refit the oil filler cap securely and check the oil level again when the engine is fully warm Oil Filter The cartridge type oil filter is mounted at the right hand front of the engine and is accessible only from beneath The filter should be renewed along with the engine oil at intervals specified in the Maintenance Schedule The oil filter housing incorporates a drain plug...

Page 70: ... arm with the corresponding drilling in the baseplate and insert a 5mm rod or hex key to hold the tensioner in the released position Slide the belt off the pulleys When reinstalling the belt retain the original direction of rotation and ensure that the belt ribs are correctly located on each drive pulley before finally fitting over the tensioner pulley Rotate the tensioner counterclock wise to rel...

Page 71: ...nder and the bracket securing the flexible hose to the trans mission and place aside without disturbing the hydraulic line 13 Earth braid Release the earth braid from the transmission case 14 Exhaust Release the exhaust downpipe from the catalytic converter 15 PAS Release the feed and return pipes from the PAS pump and collect the draining fluid 16 A C Disconnect the high and low pressure a c pipe...

Page 72: ...EJ 7 ENGINE REPAIR Engine repair information is contained on CD T000T1506 Toyota SC03T0U and by following the links Insert disc XML Service Information Directory will automatically open up If not open the CD and select rm03t0u index HTML Then Technical Description New car features NM01M0U ENGINE 2GR FE ENGINE Then select from the menu for an overview of the engine features Insert disc HTML Global ...

Page 73: ... Lotus Service Notes Section EMR Page 1 ENGINE MANAGEMENT SECTION EMR Sub Section Page Diagnostic Trouble Code List EMR 1 3 CAN Bus Diagnostics Lotus TechCentre EMR 2 80 2009 02 ...

Page 74: ...e 2 Lotus Service Notes Section EMR Notes Cylinder Numbering viewed from above LH cylinder bank 2 6 4 2 Rear of engine Front of engine flywheel end auxiliary drive belt end 5 3 1 RH cylinder bank 1 2009 02 ...

Page 75: ...Absolute Pressure Barometric Pressure Circuit Range Performance P0107 Manifold Absolute Pressure Barometric Pressure Circuit Low Input 16 P0108 Manifold Absolute Pressure Barometric Pressure Circuit High Input 16 P0111 Intake Air Temperature Sensor 1 Circuit Range Performance P0112 Intake Air Temperature Sensor 1 Circuit Low 17 P0113 Intake Air Temperature Sensor 1 Circuit High 17 P0116 Engine Coo...

Page 76: ...r 1 Circuit High 36 P0332 Knock Sensor 2 Circuit Low 36 P0333 Knock Sensor 2 Circuit High 36 P0335 Crankshaft Position Sensor A Circuit Range Performance 37 P0341 Camshaft Position Sensor A Circuit Range Performance Bank 1 38 P0346 Camshaft Position Sensor A Circuit Range Performance Bank 2 38 P0351 Ignition Coil A Primary Secondary Circuit 39 P0352 Ignition Coil B Primary Secondary Circuit 39 P03...

Page 77: ...ontrol Motor Circuit High 69 P2104 Throttle Actuator Control System Forced Idle 70 P2105 Throttle Actuator Control System Forced Engine Shutdown 70 P2106 Throttle Actuator Control System Forced Limited Power 71 P2107 Throttle Actuator Control Module Processor 71 P2108 Throttle Actuator Control Module Performance 72 P2122 Throttle Pedal Position Sensor Switch D Circuit Low 72 P2123 Throttle Pedal P...

Page 78: ...essor Lock Sensor Circuit 77 U0101 Lost Communications with TCM 78 U0122 Lost Communications with VDCM 78 U0127 Lost Communications with TPMS 78 U0316 Software Incompatible with VDCM 79 When applicable reference may be made under the Notes heading to a page in the Toyota service manual This information should be used only for diagnosis and connection detail of the sensor The Evora uses a Lotus ECU...

Page 79: ... position Cruise Control Multi function Input Determines driver request for cruise control Electronic Throttle Control Motor Actuates engine throttle Injector Circuit Cylinder 1 Regulates fuel injected into cylinder 1 Injector Circuit Cylinder 2 Regulates fuel injected into cylinder 2 Injector Circuit Cylinder 3 Regulates fuel injected into cylinder 3 Injector Circuit Cylinder 4 Regulates fuel inj...

Page 80: ... Conditioning Control Relay Actuates air conditioning compressor Air Conditioning Control Valve Regulates air conditioning compressor load Coolant Recirculation Pump Actuates coolant recirculation pump Noise Flap Solenoid Actuates air intake flap vacuum control ABS Provides vehicle wheel speed information Battery Provides electrical power 2009 02 ...

Page 81: ... Lotus Service Notes Section EMR Page 9 EMR 3 COMPONENT LOCATION em239 O2 O2 O2 O2 2009 02 ...

Page 82: ...Page 10 Lotus Service Notes Section EMR em240 2009 02 ...

Page 83: ... oil pressure applied to the vanes A 50 duty cycle applied to the valve will hold the valve current timing by preventing oil flow from the VVT controller housing a duty cycle less than 50 will retard the valve timing a duty cycle greater then 50 will advance the valve timing The ECM regulates this duty cycle based on the feedback signal from the respective camshaft position sensor to optimise the ...

Page 84: ...nted on the front end of the crankshaft The camshaft position sensor is used to determine camshaft position from a three vane reluctor on the rear end of the inlet and exhaust camshaft Fault codes P0016 P0017 P0018 P0019 indicate a mechanical timing error such as incorrectly set or jumped cam timing Monitor Continuous Enable Criteria Engine running from cranking up to 4 seconds Disable Criteria No...

Page 85: ...Intake Valve Control Solenoid Circuit High Bank2 P0085 Exhaust Valve Control Solenoid Circuit Low Bank2 P0086 Exhaust Valve Control Solenoid Circuit High Bank2 Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes P0076 P0079 P0082 P0085 VVT control valve open circuit or short to ground P0077 P0080 P0083 P0086 VVT control valve circuit short to battery vol...

Page 86: ...ctor Description ECU Pin ECU Connector 1 IAT Signal J3 48 Way Centre 2 IAT Ground E3 48 Way Centre 3 Battery Voltage 4 MAF Ground J4 48 Way Centre 5 MAF Signal G1 48 Way Centre Sensor characteristics 0 330 g sec Typical values 1 5 5 0 g sec idle 5 0 15 0 g sec 2500rpm elevated idle no load P0101 Monitor Continuous Enable Criteria Engine running Engine speed 1500rpm Engine speed 3510rpm Fuel Learns...

Page 87: ...d Diagnostic Mask The MIL will be illuminated if the faults are present for 2 consecutive trips P0103 Monitor Continuous Enable Criteria Engine running Disable Criteria None Malfunction Criteria Voltage at ECU 4 86V for time 1 5 secs Potential failure modes MAF sensor circuit short to ECU supply voltage Diagnostic Mask The MIL will be illuminated if the faults are present for 2 consecutive trips 2...

Page 88: ...or is located internally within the ECU and measures atmospheric pressure This parameter is required to compensate the mass air flow when the vehicle is operated at higher altitudes P0106 P0107 P0108 Monitor Continuous Enable Criteria Engine running Disable Criteria None Malfunction Criteria P0107 Voltage at ECU 1 08V for time 1 5 secs P0108 Voltage at ECU 4 98V for time 1 5 secs Potential failure...

Page 89: ...AT sensor is a thermistor device which changes resistance with temperature As air intake temperature decreases the thermistor resistance value increases and conversely as air temperature increases so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 IAT Signal J3 48 Way Centre 2 IAT Ground E3 48 Way Centre 3 Battery Voltage 4 MAF Grou...

Page 90: ...ircuit Sensor failure Diagnostic Mask The MIL will be illuminated if these faults are present for 2 consecutive trips P0113 Monitor Continuous Disable Criteria None Enable Criteria Engine running Malfunction Criteria Inlet air temperature 40 C 104 F for time 1 5 secs Potential failure modes Signal open circuit Sensor failure Diagnostic Mask The MIL will be illuminated if these faults are present f...

Page 91: ...s Sensor Connector Description ECU Pin ECU Connector 1 Ground C3 48 Way Centre 2 Signal G2 48 Way Centre Sensor characteristics 20 C 4 F 13 84 16 33 KΩ 20 C 68 F 2 31 2 58 KΩ 80 C 176 F 0 310 0 326 KΩ 110 C 230 F 0 1399 0 1435 KΩ P0116 Monitor Continuous Disable Criteria None Enable Criteria 1 Engine running 1000 seconds Malfunction Criteria 1 Engine coolant temperature 40 C 104 F Enable Criteria ...

Page 92: ...ling system problem Diagnostic Mask The MIL will be illuminated if these faults are present for 2 consecutive trips P0118 Monitor Continuous Disable Criteria None Enable Criteria Engine running Malfunction Criteria Coolant temperature 38 C 36 F for time 1 5 secs Potential failure modes Signal open circuit Sensor failure Diagnostic Mask The MIL will be illuminated if these faults are present for 2 ...

Page 93: ...ry between 0 V and 5 V in proportion to the throttle valve opening angle and are transmitted to the VTA terminals of the ECU Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 ETB ve M1 48 Way Centre 2 ETB ve L2 48 Way Centre 3 Ground C4 48 Way Centre 4 TPS 1B Signal F3 48 Way Centre 5 TPS 1A B V Ref E4 48 Way Centre 6 TPS 1A Signal F2 48 Way Centre Sensor characteristics 0 0 ...

Page 94: ...a None Disable Criteria None Malfunction Criteria Signal voltage 2 146V Potential failure modes Signal short circuit Reference voltage open circuit Reference voltage short to ground Sensor failure Diagnostic Mask The MIL will be illuminated if fault is present Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening...

Page 95: ...voltage open circuit Reference voltage short to ground Sensor failure Diagnostic Mask The MIL will be illuminated if fault is present Notes A maximum throttle opening of 15 may be imposed due to this single code In the case of multiple codes a mechanically sprung 7 opening may be applied 2009 02 ...

Page 96: ...Page 24 Lotus Service Notes Section EMR Coolant Thermostat USA only P0128 Coolant Thermostat Coolant Temperature Below Thermostat Regulating Temperature 2009 02 ...

Page 97: ... plate in contact with the air is electrically negative due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive This will cause a difference in electrical potential to develop between the two plates Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaus...

Page 98: ...mination Sensor wire shorted to heater voltage Diagnostic Mask The MIL will be illuminated if these faults are present for 2 consecutive trips P0133 Bank1 or P0153 Bank2 Monitor Continuous Disable Criteria P0116 P0117 P0118 Coolant temperature sensor faults P0101 P0102 P0103 MAF sensor faults P0335 P0500 Crank or vehicle speed faults P0131 P0132 P0134 P0135 Pre catalyst oxygen sensor faults for Ba...

Page 99: ... Engine run time 30 seconds Engine is not at idle Engine is in closed loop fuel control O2 sensor ready Malfunction Criteria Set when the sensor fails to switch above 673mV and below 400mV within a 60 second period Potential failure modes Sensor connector and wiring should be checked for corrosion and loose connections Gas leak in exhaust system Diagnostic Mask The MIL will be illuminated if these...

Page 100: ...e due to the oxygen in the atmosphere and the plate in contact with the exhaust gases is electrically positive This will cause a difference in electrical potential to develop between the two plates Thus the voltage across the platinum plates ranges approximately from 100 millivolts to 900 millivolts depending on the oxygen content of the exhaust gases Thus when the air fuel mixture is rich the oxy...

Page 101: ... 2 consecutive trips P0138 P0158 Monitor Continuous Enable Criteria Engine running Disable Criteria None Malfunction Criteria Set when the sensor operates above 1200mV for more than 1 5 seconds consecutively for a specified number of times Potential failure modes Check and rectify any front sensor fault code as they may be causing the fault code to be set Catalyst Diagnostic Mask The MIL will be i...

Page 102: ...or connector and wiring should be checked for corrosion and loose connections Catalyst Gas leak in exhaust system Diagnostic Mask The MIL will be illuminated if these faults are present for 2 consecutive trips P0141 P0161 Monitor Continuous Enable Criteria Engine run time 20 seconds Disable Criteria None Malfunction Criteria Set when the heater output is greater than 1900mA or less than 250mA for ...

Page 103: ... Disable Criteria P0171 P0172 P0106 P0107 P0108 Baro sensor faults P0131 P0135 Oxygen sensor faults P0300 P0301 P0302 P0303 Misfire faults P0111 P0112 P0113 Intake air temperature faults Disable Criteria P0174 P0175 P0106 P0107 P0108 Baro sensor faults P0151 P0155 Oxygen sensor faults P0300 P0304 P0305 P0306 Misfire faults P0111 P0112 P0113 Intake air temperature faults Malfunction Criteria P0171 ...

Page 104: ... 14 7 1 under normal driving conditions These codes will also be set if the relevant bank fuel learn injector dead time is less than 450 micro sec onds Potential failure modes Fuel pressure too high Leaking fuel injector Restriction in the exhaust system or air intake filter Erratic throttle position sensor MAF fault O2 sensor fault Ignition fault Diagnostic Mask The MIL will be illuminated if a f...

Page 105: ...r circuits each of which controls an injector When the engine is running the ECU continuously monitors the injector circuit feedback signals The monitored feedback signal should be low voltage when the injector is ON and high voltage when the injector is OFF Component connections Injector ECU Pin ECU Connector 1 H4 32 Way Left 2 H3 32 Way Left 3 H2 32 Way Left 4 H1 32 Way Left 5 G4 32 Way Left 6 G...

Page 106: ...Ignition Coil Feedback D2 D2 D2 D2 D2 D2 32 Way Left 3 Coil Output Logic F4 F3 F2 F1 E4 E3 32 Way Left 4 Ground Malfunction Criteria The operation of all the misfire codes is the same the last digit relates to the misfire involved i e a code P0303 indicates there is a problem with cylinder number 3 P0300 indicates the misfire is random and not linked to one particular cylinder Monitor Continuous E...

Page 107: ...g or related codes MAF meter or related codes Connectors and wiring for signs of corrosion or loose connections Spark plug coil cylinder compression PCV system hoses Fuel pressure Coolant temperature sensor Vacuum hoses ECU Diagnostic Mask The MIL will be illuminated if a fault is present for two consecutive trips 2009 02 ...

Page 108: ...nd other similar sounding noises Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Sensor input D1 48 Way Centre 2 Bank 1 Ground C1 48 Way Centre 3 Bank 2 Sensor input D2 48 Way Centre 4 Bank 2 Ground C2 48 Way Centre Monitor Continuous Enable Criteria Engine running Malfunction Criteria P0327 This code is set when the bank 1 knock sensor signal is 0 586 V P0328 This c...

Page 109: ...onnections Sensor Connector Description ECU Pin ECU Connector 1 Sensor input A4 32 Way Left 2 Ground B2 32 Way Left Monitor Continuous Enable Criteria Engine running Disable Criteria None Malfunction Criteria 15 crank errors in succession This can occur due to no crank signal occurring whilst the cams continue to count or if there is a measured consecutive crank error Potential failure modes Senso...

Page 110: ...onnector Description ECU Pin ECU Connector 1 Inlet Bank 1 Signal A3 32 Way Left 2 Inlet Bank 1 Ground B3 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Exhaust Bank 1 Signal D4 32 Way Left 2 Exhaust Bank 1 Ground C3 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Inlet Bank 2 Signal A2 32 Way Left 2 Inlet Bank 2 Ground C2 32 Way Left 3 Supply voltage 5V D1 32 Way Left 1 Exhaust Bank 2 Signal D3...

Page 111: ...ition signals IGT for each cylinder Based on IGT signals the power transistors in the igniter cuts off the current to the primary coil which induces a spark at the spark plug connected to the secondary coil The igniter will also send an ignition confirmation signal IGF as a fail safe measure to the ECU Component connections Connector Pin Description ECU Pin ECU Connector 1 Supply Voltage Coil 1 Co...

Page 112: ...o high a fault will be indicated Sensor connections Pre catalyst oxygen sensor Sensor Connector Description ECU Pin ECU Connector 1 Bank 1 Signal G3 48 Way Centre 2 Bank 1 Ground J2 48 Way Centre 3 Bank 1 Heater Supply H3 48 Way Centre 4 Bank 1 Battery Voltage 1 Bank 2 Signal G4 48 Way Centre 2 Bank 2 Ground J2 48 Way Centre 3 Bank 2 Heater Supply H4 48 Way Centre 4 Bank 2 Battery Voltage Post cat...

Page 113: ...57 P0158 P0159 P0160 P0161 Oxygen sensor faults B2 P0171 P0172 P0174 P0175 Fuelling faults B1 B2 P0300 P0301 P0302 P0303 P0304 P0305 P0306 Misfire faults P0500 Speed sensor fault Malfunction Criteria Switch ratio between Pre Post catalytic converter O2 sensors 0 6 Potential failure modes Exhaust system leak Oxygen sensor faults Oxygen sensor heater failure Catalyst failure Diagnostic Mask The MIL ...

Page 114: ...l Leak Detection System P0441 Evaporative Emission System Incorrect Purge Flow P0442 Evaporative Emission System Leak Detected small leak P0455 Evaporative Emission System Leak Detected large leak P0456 Evaporative Emission System Leak Detected very small leak 2009 02 ...

Page 115: ... Lotus Service Notes Section EMR Page 43 2009 02 ...

Page 116: ...Page 44 Lotus Service Notes Section EMR 2009 02 ...

Page 117: ...re Sensor Switch Low P0453 Evaporative Emission System Pressure Sensor Switch High Description When the engine is running the ECU continuously monitors the status of the evaporative emission components for open circuit or short The feedback signal should be low when turned ON and high when turned OFF The following codes will be set if the above conditions are not met P0444 P0445 Sensor component c...

Page 118: ...Page 46 Lotus Service Notes Section EMR 2009 02 ...

Page 119: ...63 Monitor Continuous Enable Criteria Engine Running Disable Criteria None Malfunction Criteria P0462 Voltage 0 020V P0463 Voltage 0 684V for 1 5 secs Potential failure modes Sensor open or short circuit Fuel level sensor Diagnostic Mask The MIL will be illuminated if these faults are present for 2 consecutive trips P0461 The ECU calculates the fuel usage and determines whether the fuel level sens...

Page 120: ...r three conditions stuck when full stuck when empty or stuck midway The ECU determines if the sensor is stuck by calculating the amount of fuel used during the test period If the fuel level does not move by more than 1 litre a fault is flagged Potential failure modes Fuel level sensor wiring or connector corroded Fuel level sensor stuck Diagnostic Mask The MIL will be illuminated if these faults a...

Page 121: ...cription ECU Pin ECU Connector Fan Relay 3 F1 48 Way Right Fan Relay 2 E2 48 Way Right Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes Wiring harness problem Relay ECU Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips 2009 02 ...

Page 122: ...riteria Following conditions must occur for 5 seconds Engine speed 1800rpm and 5010rpm Baro 756 mbar Engine in a mode that indicates that the vehicle must be moving Malfunction Criteria KMH 5 kmh Potential failure modes ABS module failure CAN bus communication error to ABS controller Diagnostic Mask The MIL will be illuminated if a fault is present for two consecutive trips 2009 02 ...

Page 123: ...alfunction Criteria 1 Idle air learn value on upper limit of 1 8g s Idle speed more than 200 rpm above desired idle speed for more than 5 seconds Malfunction Criteria 2 Idle air learn value on lower limit of 1 8g s Idle speed more than 100 rpm below desired idle speed for more than 5 seconds Potential failure modes Induction system air leak Excessive engine load from front end accessory drive syst...

Page 124: ... as the evaporator temperature increases so the thermistor resistance value decreases Sensor connections Sensor Connector Description ECU Pin ECU Connector 1 Sensor signal A3 48 Way Right 1 Sensor ground K3 48 Way Right Monitor Continuous Enable Criteria Vehicle Running Disable Criteria None Malfunction Criteria P0537 Signal voltage 0 049V for 1 5 seconds P0538 Signal voltage 4 399V for 1 5 second...

Page 125: ... around 14V The ECM monitors this and will diagnose if the voltage is too high or too low Monitor Continuous Enable Criteria Engine running Disable Criteria None Malfunction Criteria P0562 Voltage Too Low 10V for 10 seconds P0563 Voltage Too High 16V for 25 5 seconds Potential failure modes Alternator fault Battery fault Diagnostic Mask The MIL will be illuminated if a fault is present for two con...

Page 126: ... Description ECU Pin ECU Connector 1 Cruise control switch input E3 48 Way Right 2 Cruise control ground K3 48 Way Right 1 Brake Switch Ground 2 Brake Switch Input C4 48 Way Right P0564 P0578 Monitor Continuous Enable Criteria None Disable Criteria None Malfunction Criteria P0564 Cruise control multifunction switch open circuit or short circuit P0578 Input other than OFF received for more than 100...

Page 127: ...teria 2 ABS indicating brakes are on but brake switch off for greater than 0 5 seconds Potential failure modes Brake switch wiring open circuit or shorted Brake switch fault Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips 2009 02 ...

Page 128: ...m for calibration data is the same as checksum saved on the previous power down P0606 checks the watchdog timer after a defined period to see if it has reset If the watchdog timer has not reset then the code has entered an unplanned loop or condition stopping it resetting the timer Monitor P0601 at ECU power up P0606 continuously while the engine running Diagnostic Mask The MIL will be illuminated...

Page 129: ...ramming process includes the Vehicle Variant Code If a new ECM has been fitted the relevant variant code needs to be programmed using the Lotus TechCentre tool Monitor During start up Disable criteria None Potential failure modes Variant code not programmed Diagnostic mask The MIL will be illuminated if fault is present 2009 02 ...

Page 130: ...n the crank relay Component connections Relay Connector Description ECU Pin ECU Connector 2 Main relay via fuse R1 4 Crank relay control G1 48 Way Right Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes P0616 Crank relay wiring open circuit or shorted to ground P0616 Fuse R1 P0617 Crank relay wiring shorted to 12V Crank relay failure Immobiliser failur...

Page 131: ...peration via a relay because of this the only fault diagnosis is of the fuel pump relay Component connections Relay connector Description ECU Pin ECU Connector 1 Rear ignition relay fuse R7 2 Fuel pump relay control H2 48 Way Right Monitor Continuous Enable Criteria Ignition on Disable Criteria None Potential failure modes P0628 fuel pump relay wiring open circuit or shorted to ground P0628 fuse R...

Page 132: ... process includes the Vehicle Identification Number VIN If a new ECM has been fitted this operation is performed using the Lotus TechCentre tool Monitor During start up Enable Criteria Engine running for up to 4 seconds Disable Criteria None Potential failure modes VIN not programmed Diagnostic Mask The MIL will be illuminated if fault is present 2009 02 ...

Page 133: ...tinuous Enable Criteria 1 Engine running Disable Criteria 1 Electronic throttle fault P2135 P0122 P0122 P0222 or P0223 present Throttle demand transient condition Malfunction Criteria 1 TPS error 3 for 7 5 secs Enable Criteria 2 Ignition on Disable Criteria 2 Electronic throttle fault P2135 P0122 P0122 P0222 or P0223 present Malfunction Criteria 2 Throttle not able to find closed position during b...

Page 134: ...ECU Connector 1 Ignition supply fuse R11 2 AC clutch relay control F2 48 Way Right Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes P0646 A C compressor relay wiring open circuit or shorted to ground P0646 Fuse R11 P0647 A C compressor relay circuit shorted to 12V A C compressor relay failure ECU output circuit failure Diagnostic Mask The service ligh...

Page 135: ... turns on the VIM control valve to close the VIM Under all other conditions the VIM control valve is usually off and the VIM is open Component connections Connector Description ECU Pin ECU Connector 1 Ignition supply fuse R8 2 VIM control valve control L4 48 Way Central Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes P0661 VIM wiring open circuit or ...

Page 136: ...sor input for malfunctions Component connections Connector Description ECU Pin ECU Connector A Ground K3 48 Way Right B Clutch position sensorsignal B1 48 Way Right C Reference voltage F4 48 Way Right P0806 Monitor Continuous Enable Criteria Maximum and minimum clutch position measured over 15 gear changes Disable Criteria None Malfunction Criteria Voltage difference between maximum and minimum of...

Page 137: ...it or shorted to ground P0808 Clutch sensor ECU input circuit shorted to 5V or 12V Clutch sensor failure Clutch pedal failure ECU input circuit failure Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault has been present for the previous two trips 2009 02 ...

Page 138: ...ose one of the air cleaner inlets When the engine speed is greater than a specified value the ECM activates the VSV and the applied vacuum activates the AICV to open both of the air cleaner inlets Component connections Connector Description ECU Pin ECU Connector 1 Ignition supply fuse R8 2 VSV control B1 48 Way Central Monitor Continuous Enable Criteria Engine running Disable Criteria None Potenti...

Page 139: ...248 F Engine speed between 480 8010rpm Engine speed transient 15rpm Altitude 8000 ft 2438 m Baro 756mbar Fuel level 5 litres 1 3 US gallons Engine load greater than 14 25 depending on engine speed Disable Criteria DFCO enabled Deceleration Fuel Cut Off Rough road MAF faults Malfunction Criteria P1301 Emissions Failure Misfire percentage 7 measured over 1000 engine revolutions P1302 Catalyst Damage...

Page 140: ...r a short period of idle to aid heater performance Component connections Connector Description ECU Pin ECU Connector 1 Recirc pump driver M1 48 Way Right 2 Main relay via fuse R4 Monitor Continuous Enable Criteria P2602 continuous P2603 engine running Disable Criteria None Potential failure modes P2602 pump wiring open circuit or shorted to ground P2602 fuse R4 P2603 pump circuit ECM side shorted ...

Page 141: ...uator control motor open circuit Throttle Actuator Control Motor Circuit Low P2102 Throttle actuator control motor circuit low Monitor Continuous Enable Criteria None Disable Criteria None Potential failure modes Throttle actuator control motor short to ground Throttle Actuator Control Motor Circuit High P2103 Throttle actuator control motor circuit high Monitor Continuous Enable Criteria None Dis...

Page 142: ...es Electronic throttle fault Note This code indicates action taken by the ECU and will always be accompanied by another code which has caused this action Throttle Actuator Control System Forced Engine Shutdown P2105 Throttle actuator control system forced engine shutdown Description If a problem is detected which could result in engine speed runaway or if sufficient control of engine speed is lost...

Page 143: ...ing Disable Criteria None Potential failure modes Electronic throttle fault Note This code indicates action taken by the ECU and will always be accompanied by another code which has caused this action Throttle Actuator Control Module Processor P2107 Throttle actuator control module processor Description The ECU contains two processors dedicated to the throttle pedal and throttle valve potentiomete...

Page 144: ...sition sensor D circuit low Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU Note that the potentiometers operate on 5 volts Enable Criteria None Disable Criteria None Potential failure modes Signal short circuit 0 283 V Reference voltage open circuit Reference voltage short to ground Sensor failure Notes A maximum thrott...

Page 145: ...prung 7 opening may be applied Pedal Position Sensor E Circuit Low P2127 Pedal position sensor E circuit low Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU Note that the potentiometers operate on 5 volts Enable Criteria None Disable Criteria None Potential failure modes Signal short circuit 0 283 V Reference voltage ope...

Page 146: ...g 7 opening may be applied Throttle Position Sensor A B Voltage Correlation P2135 Throttle position sensor A B voltage correlation Description Two potentiometers are built into the throttle actuator unit in order to provide a throttle position signal to the ECU Two processors within the ECU compare the two output signals which should match within a defined tolerance Note that the potentiometers op...

Page 147: ...ria None Disable Criteria None Potential failure modes PPS1 reading incorrectly PPS2 reading incorrectly Notes A maximum throttle opening of 15 may be imposed Throttle Actuator Control System High Airflow Detected P2173 Throttle actuator control system high airflow detected Description The mass air flow is compared with the throttle position to determine whether an incorrect correlation exists Ena...

Page 148: ...nt connections Connector Description ECM Pin ECM Connector 1 Control valve driver K3 48 Way Centre 2 Ignition via rear ign relay Monitor Continuous Enable Criteria Engine running Disable Criteria None Potential failure modes P2612 valve wiring open circuit or shorted to ground P2612 loss of power from rear ignition relay P2613 valve circuit ECM side shorted to battery voltage Valve failure ECM out...

Page 149: ...nnector 1 Lock sensor ve C1 32 Way Left 2 Lock sensor ve B1 32 Way Left Monitor Continuous Enable Criteria Engine running Disable Criteria P0646 P0647 A C compressor clutch fault Malfunction Criteria A C compressor speed error greater than 20 Potential failure modes A C compressor clutch mechanism slipping or seized A C compressor drive belt slipping Lock sensor wiring Lock sensor failure ECM inpu...

Page 150: ...odule VDCM via the CAN bus If these CAN bus communications have been interrupted the ECM will register a diagnostic code Potential failure modes CAN wiring VDCM control module failure CAN bus corruption by another module on bus Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault was present on the previous trip Lost Communications with TPMS U0127 Lo...

Page 151: ...e vehicle variant code If not the above code will be set and the ECM will not respond to torque requests from the VDCM Potential failure modes The ECM has been programmed with an incorrect variant code which does not match vehicle VDCM level VDCM error Diagnostic Mask The service light will be illuminated for 30 seconds after engine start if the fault was present on the previous trip 2009 02 ...

Page 152: ... restraint anti lock braking and related features instrument pack and onboard diagnostics A stand alone lap top PC loaded with Lotus Techcentre software allows the CAN based serial data to be read A Vehicle Communication Device T000T1472F introduced for the Europa model is used to connect the vehicle to the laptop Lotus Techcentre Engine programming live data display diagnostics of engine ABS and ...

Page 153: ...ice Notes Section FL TRANSMISSION SECTION FL Sub Section Page Introduction FL 1 3 Gearchange Mechanism FL 2 3 Lubrication FL 3 6 Driveshafts FL 4 6 Transmission Removal Replacement FL 5 10 Transmission Overhaul FL 6 10 ...

Page 154: ...re used Constant mesh type reverse gear is used Slide ball bearings are used for the shift fork shafts and shift select lever shaft Rolling type rock ball is used for shift select lever shaft 288NF03Y View from A Side Sliding Ball Bearings Sliding Ball Bearings Shift Fork Shafts A Sliding Ball Bearing Shift Select Lever Shaft Sliding Ball Bearing Output Shaft No 1 Input Shaft Triple cone Synchrome...

Page 155: ...d Engaging Reverse Gear With the vehicle at a complete stand still pause for a moment with the clutch pedal fully depressed before moving the lever to the left raising the lift collar beneath the knob and then further to the left over a spring detent before finally pushing forwards to engage the gear A two cable mechanism is used to connect the gearchange lever with the transmission one cable shif...

Page 156: ...counter clockwise before re attaching to the bellcrank and testing Once a setting is found which allows smooth fore aft lever movement whilst abuting against the inhibitor block secure the ball joint socket with the locknut Note that adjustment is available also at the transmission end of the cable Raise the reverse inhibit gear lever collar and check that reverse gear can be engaged Refit the shr...

Page 157: ...rking brake cable from the lever and disconnect the parking brake tell tale switch Mounting frame Release the gear lever mounting frame from the support channel and withdraw Release the support channel Remove the 12 screws securing the support channel to the floor of the chassis tub to allow the gear cables to be released from the P clips inside the support channel Release cables rear Release the ...

Page 158: ...eel hub The longer right hand driveshaft assembly features an outrigger bearing bolted to the right hand side of the cylinder block with a shaft extending from the inboard CV joint into the transmission housing The inboard joints are of a plunging tripod design to accommodate driveshaft length variation with sus pension travel whereas the outboard joints are high efficiency 6 ball fixed length typ...

Page 159: ...Lubricant Remove transmission drain plug and drain off approx 1 litre of oil into a clean container for re use 5 LH Driveshaft The left hand driveshaft inboard joint is retained in the transmission by a round section circlip The joint may be removed by applying a shock pull to the C V joint body using a slide hammer with a forked end CAUTION Any attempt to withdraw the inboard joint by pulling on ...

Page 160: ... carefully inspected Tilt the ball type inner race or spider rollers to one side to expose each driving surface Severe pitting galling play between ball and its cage window any cracking or damage to the cage or pitting galling or chips in raceways call for joint replacement If the joint is found to be serviceable it must be repacked with the special grease provided Pack the grease into the joint i...

Page 161: ...ss a new bearing into the housing and retain with a new circlip Then use special press tool T000T1438F to press the inner race of the bearing up to the shoulder on the shaft and retain with a new circlip 7 Use special press tool T000T1439F to press the bearing dust shield onto the shaft and position as shown in the illus tration 8 Press the inboard dust shield onto the end of the shaft to the dime...

Page 162: ...racket to the transmission adaptor plate and remove the bracket 4 Ensure suitable independent support of the engine and transmission units before releasing the clutch housing from the engine From beneath remove the two bolts securing the dirt shield in the clutch housing aperture Remove the 3 bolts from the engine side of the lower section of the adaptor plate Remove the 5 bolts from the transmiss...

Page 163: ...n GJ WHEELS TYRES SECTION GJ Sub Section Page General Description GJ 1 2 Tyre Pressure Monitoring System TPMS GJ 2 2 Wheels GJ 3 3 Wheel Bolts GJ 4 4 Tyres GJ 5 4 Winter Tyres Snow Chains GJ 6 5 Punctured Tyre Emergency Inflator GJ 7 6 ...

Page 164: ... shake it is very important that the radial and lateral run out of the tyres are to the high standard required by Lotus Cars If any difficulty is experienced with replacement tyres refer to the tyre manufacturer The Yokohama Advan Sport tyres fitted to the Evora are suitable for all normal weather conditions The tyre characteristics include good feedback feel from the road surface to the steering ...

Page 165: ...cation Failed C0800 TPMS Module Supply Voltage Below 9V Above 18V U2103 TPMS Communications Malfunction In the first instance the car should be driven gently at 40 mph in order to optimise conditions for sensor recognition If the fault persists the following action should be considered 550 551 558 most likely a TPMS module problem renew 75A B C D most likely a pressure sensor renew 777 Most likely...

Page 166: ...ured before applying torque Note that an alignment mark is provided on the coded bolt head and adaptor tool to aid refitting The spline drive extension and the coded adaptor tool are stowed in the vehicle tool pouch and should remain with the car at all times to allow servicing or repairs to be performed GJ 5 TYRES The Pirelli P Zero tyres fitted to the Evora are suitable for all normal weather co...

Page 167: ...s are moulded into the bottom of the tread grooves at intervals around the tyre indicated by small pointers on the outer tread blocks In order that these tyres maintain their design performance on snow covered roads the minimum tread depth is designated as 4 mm which is reflected in the height of a secondary set of wear indicators Note that the W drive tread pattern is asymetrical so that when fit...

Page 168: ...sol should be carried at all times in the designated stowage position Never carry in the passenger compartment As soon as a puncture is suspected the car should be stopped at the first safe opportunity Continued driving on a deflated tyre will cause irreparable damage to the tyre Directions for use of the aerosol Before using carefully read all the instructions on the canister or on any literature...

Page 169: ...teering Rack Operation HI 2 3 PAS Fluid Check Refill Procedure HI 3 6 Steering Wheel HI 4 6 Steering Column Assembly HI 5 7 Intermediate Column HI 4 8 Track Rod Ends Rack Gaiters HI 5 9 Front Wheel Alignment Rack Gaiters HI 5 8 Rack Pinion Assembly Removal Replacement HI 6 10 PAS Pump Testing Procedure HI 7 11 ...

Page 170: ...assembly Intermediate column Upper universal joint Lower column Collapsible joint Lower universal joint Pinion shaft Pinion end solid mountings Rack and pinion assembly Rubber sleeve Non pinion end clamp Tie rod Mounting bracket to chassis Alloy insert Shim plate Track rod h62 ...

Page 171: ...tie rods from each end of the rack connect via length adjustable track rods to forward facing steering arms integral with the forged steel front hub carriers with outer pivot points positioned laterally to provide a 32 Ackermann effect and vertically for a toe out on bump characteristic The rack and pinion assembly is geared to provide 47 4mm rack travel for one steering wheel revolution with 2 86...

Page 172: ... the torsion bar is determined by the force applied at the steering wheel and is proportional to the loading at the front tyres These forces tend to be highest when manoeuvering at low speed e g parking and result in the greatest angular displacement between valve rotor and sleeve The valve body incorporates 4 ports inlet from the engine driven pump outlet return to the reservoir connection to the...

Page 173: ... Low pressure line from reservoir to pump Engine driven pump Supply line to valve body Low pressure return line to reservoir Supply return to RH cylinder Valve body Supply return to LH cylinder Hydraulic seal Track rod Rack pinion gear RH rack cylinder LH rack cylinder Sealed piston h62 ...

Page 174: ... to the effort applied at the wheel and the resistance at the tyres Effort is high typically at slow vehicle speeds or when parking When the bar twists the angular position of the rotor relative to the valve sleeve alters with the result that the ports to cylin der 1 become biased towards the pressurised supply and the ports to cylinder 2 biased to the reservoir return port at low pressure Hence a...

Page 175: ...nking the engine for a few moments with ignition disabled After draining the fluid or after the loss of fluid during the course of repairs or hydraulic system discon nection Fill the reservoir with an approved fluid Raise the front of the car and turn the steering wheel slowly from lock to lock several times Top up fluid level if necessary Lower the car start the engine and idle for a few minutes ...

Page 176: ... the 4 screws to release the cover from the wheel reverse side 6 Refit in reverse order to removal but before fitting the steering wheel it is essential to centralise the rotary connector or the unit will be broken when lock is applied Turn the connector fully clockwise until it tightens and then turn back just over two turns until the red marker appears in the square window Note that this instruc...

Page 177: ...event of a heavy forward load being applied to the steering wheel such as may occur in an accident the rearward part of the bracket complete with upper column assembly is able to break free from the scuttle pushing the column B through the lower bearing and collapsing the intermediate column After any such oc curence the complete steering column assembly should be replaced If in any circumstances ...

Page 178: ...ock spindle from now until the lock barrel is securely installed c Turn the plastic insert a quarter turn clockwise and withdraw With the key turned to position 1 insert the lock barrel into the lock housing and ensure that the spring loaded pin is engaged in the housing locating hole d The lock spindle may now be released Continue the assembly procedure in reverse to removal with the following no...

Page 179: ... Steering Rack Gaiters The convoluted gaiters sealing each end of the steering rack housing to the tie rods should be inspected at service intervals and replaced immediately if found to be torn cracked or otherwise damaged The ingress of dirt or water into the rack housing will cause rapid deterioration of the track rod inner ball joints rack end bushes and rack and pinion mechanism requiring repl...

Page 180: ...n the u j pinch bolt to 25 Nm Before securing the rack housing refit the feed and return pipes to the pinion housing using new or an nealed washers Torque tighten M14 return to 18 25 Nm M16 feed to 25 30 Nm Torque tighten housing fixing bolts 4 off to 45 Nm Torque tighten track rod end ball pin nuts to 45 Nm Torque tighten the anti roll bar clamp mounting plate to subframe bolts 8 off to 24 Nm Tor...

Page 181: ...heating will occur Minimum fluid pressure 7800 to 8300 kPa 1100 to 1200 psi 10 Disconnect the gauge pipes and refit the banjo union to the pump Bleed the system of air see above hi 8 pas pump removal inspection The vane type constant displacement hydraulic pump is mounted on the right hand front of the cylinder block and is driven by the automatically tensioned multi rib auxiliary belt from the cr...

Page 182: ...efore inserting the plate into the housing with the notch on the rear side rim aligned with the notch in the housing Fit the cam ring into the housing with the inscribed mark facing rearwards and the notch aligned with the notch in the front plate Fit the vane rotor onto the shaft and lubricate before sliding the 10 vanes into their slots Retain the rotor by installing a new snap ring into the sha...

Page 183: ...eplacement front rear JL 4 5 Parking Brake Mechanism JL 5 7 Brake Discs JL 6 8 Brake Callipers JL 7 9 Brake Master Cylinder JL 8 9 Vacuum Servo Unit JL 9 10 Pedal Box JL 10 12 ABS Theory of Operation JL 11 13 ABS Electro Hydraulic Unit JL 12 20 Wheel Speed Sensors JL 13 21 Data Link Connector DLC JL 14 21 Special Tools JL 15 21 Lotus TechCentre Checking Procedures JL 16 22 ...

Page 184: ...Page 2 Lotus Service Notes Section JL GENERAL LAYOUT TBA ...

Page 185: ...m The lever activates a primary cable which exits the cabin at the front of the fuel tank bay and turns through 90 to connect to a balancing yoke at the front of the engine bay The yoke forms the abutment for the primary outer cable with the inner cable continuing through a slot in the yoke to link to the RH secondary cable The opposite end of the yoke connects to the LH secondary cable with both ...

Page 186: ...e affected by dragging brakes faulty wheel bearings or other related faults The ABS controller constantly monitors the anti lock system for faults and lights a fascia tell tale if a prob lem is detected Information stored in the computer s memory may be accessed via the Lotus TechCentre in order to facilitate diagnosis of system faults see later JL 2 TELL TALE LAMPS Two tell tale lamps are provide...

Page 187: ...ome service operations such as replacing brake pads will result in the displacement of fluid from the hydraulic circuit back into the reservoir In order to prevent fluid overflowing from the reservoir it may be nec essary to remove some fluid using a syringe Renewal of Brake Fluid Brake fluid absorbs water from the atmosphere over a period of time i e is hygroscopic resulting in a lowering of the ...

Page 188: ...le calliper pliers to provide the necessary space This action will return fluid to the master cylinder such that some fluid may need to be removed by syringe in order to prevent overflowing Do not lever between the disc and piston or damage to both components may be caused Note that new pads are supplied with an anti squeal overlay applied to the backplate and the edge of the pad material should b...

Page 189: ...rovides a bal anced expanding force to the lower ends of the parking brake shoes which operate within brake drums formed integrally with the rear brake discs The upper ends of the shoes pivot against opposite ends of an adjustable length abutment with access to the toothed adjuster screw available via a hole in the brake backplate The parking brake should be applied by pulling up the lever with hi...

Page 190: ...h is sandwiched between the wheel and its hub flange being centralised by the hub spigot and transmitting torque via the clamping force of the road wheel bolts A countersunk screw is used to retain the discs for convenience when servicing The 350 x 32 mm front discs and the 332 x 26 mm rear discs are all internally ventilated with directionally curved cooling vanes and have cross drilling to aid p...

Page 191: ...ed as LF RR and LR Each calliper is secured to its hub carrier by two bolts disposed in a plane perpendicular to the disc axis with the front callipers mounted behind the axle line and the rear callipers ahead of the axle The brake callipers are to be dismantled or overhauled only A P Racing at Wheeler Road Seven Stars Industrial Estate Coventry CV3 4LB Front calliper fixing bolt torque 86 Nm usin...

Page 192: ...t in the servo shell and is supplied complete with the grommet The servo is of the suspended in vacuum type wherein two flexible diaphragms divide each of two sec tions within the steel shell into two chambers One pair of chambers towards the front side of each diaphragm is connected via a non return valve to the vacuum produced in the engine s inlet plenum chamber The second pair of chambers towa...

Page 193: ...rom the engine increase the force applied to the master cylinder pushrod by a factor of five The pliant reaction disc fitted between the input and output rods ensures a graduated application of servo assistance and provides pedal feedback and feel to the driver Operational Check As a quick check of servo operation proceed as follows With the engine stopped press the brake pedal several times to ex...

Page 194: ... brake and clutch pedals are fabricated from steel plate and feature synthetic bushes for maintenance free articulation on the steel pivot shaft and serrated alloy footpads The brake pedal uses a coil pull off spring and the clutch pedal is equipped with an overcentring coil spring linkage in order to reduce the pedal effort required to maintain full clutch disengagement A clutch pedal potentiomet...

Page 195: ...g the maximum braking force consistent with continued wheel rotation The system is able to monitor and independently control each of the four wheel brakes and is referred to a 4 channel system In order to achieve the required pressure modulation three basic modes are used Pressure hold Pressure reduction Pressure increase In order to maintain the safety provision of two entirely independent hydrau...

Page 196: ...el for example is tending to lock i e its deceleration is too rapid with too great a speed differential with the other wheels 2 The connection between the master cylinder and the LH front brake circuit is interrupted by the isolation valve and the rate of slip increase is reduced 3 If the wheel speed continues to depart significantly from vehicle speed the dump valve is energised to reduce pressur...

Page 197: ...licated for the rear brake circuit which remains completely independent of the front circuit Normal Braking During normal braking when the wheel speed sensors indicate no imminent wheel locking the ABS is inactive The solenoids are unenergised so that the isolation valves are sprung open and the dump valves sprung closed Hydraulic fluid from the master cylinder enters the modulator via the inlet p...

Page 198: ... anti lock sequence is to isolate that wheel brake circuit from the master cylinder The ECM energises the isolator valve solenoid which closes the valve against spring pressure and maintains existing pressure in the left hand front brake circuit regardless of any increase in pedal pressure Isolation valve energised and closed Pressure trapped in LHF brake line Inlet from master cylinder j149b ...

Page 199: ...fluid into the low pressure accumulator shared with the RH front circuit Very short activation pulses are used to maintain close control of the pressure reduction and to limit the reduction to that required to restore wheel speed Fluid displaced from the wheel brake circuit is stored in the front brake accumulator against spring pressure and is also used to prime the hydraulic pump Isolation valve...

Page 200: ... sensation felt by the driver with the pressure pulsations from the pump damped and quietened by the restriction of the orifice When wheel speed has been restored and the brake pressure is required to increase the isolation valve is momentarily opened to allow master cylinder pump pressure to raise the pressure in the wheel brake circuit in increments If imminent locking is again sensed the isolat...

Page 201: ...he dump valve closed solenoid de energised to seal off the pressure relief circuit The pump will remain running for a short time to help drain any fluid from the accumulator whose piston is returned to its start position under the action of the spring and return the fluid to the master cylinder reservoir Isolation valve de energised and open Output to LHF brake Inlet from master cylinder Pump runs...

Page 202: ...ut FL Front left FR Front right RR Rear right RL Rear left To Remove Electro Hydraulic Unit When removing the unit beware of dripping brake fluid and take appropriate precautions to prevent dam age to paintwork 1 Raise the vehicle and remove the front undertray Remove the module protective cover 2 Switch off the ignition before pressing the release tab and folding back the cam lever to disconnect ...

Page 203: ...ndard to allow high speed communication between modules and controllers via a serial data bus The bus is a circuit linking the modules to the controller consisting of a pair of cables twisted together to reduce electromagnetic interference and carrying a square wave voltage signal corresponding to 0 s and 1 s coded in such a way as to identify and prioritise the individual messages On the Evora CA...

Page 204: ...LC see JL 14 This tool allows the display of any stored trouble codes and sensor readings as well as allowing manual operation of actuators The facilities available include Viewing fault codes wheel speeds valve activities Clearing fault codes Generating valve motor activities Reading EEPROM contents Reading ECM identification Updating ECM calibration Important Notes Whenever the Lotus TechCentre ...

Page 205: ... command FL REL SOL FDBK Front left solenoid release feedback FR HOLD SOL CMD Front right solenoid hold command FR HOLD SOL FDBK Front right solenoid hold feedback FR REL SOL CMD Front right solenoid release command FR REL SOL FDBK Front right solenoid release feedback RL HOLD SOL CMD Rear left solenoid hold command RL HOLD SOL FDBK Rear left solenoid hold feedback RL REL SOL CMD Rear left solenoi...

Page 206: ...ve circuit malfunction C0080 Rear left outlet solenoid valve circuit malfunction C0085 Rear left inlet solenoid valve circuit malfunction C0090 Rear right outlet solenoid valve circuit malfunction C0095 Rear right inlet solenoid valve circuit malfunction C0110 Return pump circuit open or shorted locked or shorted C0121 Valve relay circuit malfunction C0161 Brake light switch fault C0232 Brake syst...

Page 207: ...Page 25 Lotus Service Notes Section JL ...

Page 208: ...ction KJ ENGINE COOLING SECTION KJ Sub Section Page General Description KJ 1 3 Maintenance KJ 2 4 Drain Refill Procedure KJ 3 5 Radiator Cooling Fan KJ 4 6 Radiator Fan Re circ Pump Control KJ 5 7 Radiator Feed Return Pipes KJ 6 7 ...

Page 209: ...adiator Heater matrix Thermostat housing By pass pipe Heater return rail Throttle body Header tank Bleed screws Outlet housing Radiator Recirc pump feed pipe Oil flow from heat exchanger to filter Oil from pump Heater feed to heat exchanger Oil water Heater return heat exchanger k76 ...

Page 210: ...F the dual valve thermostat is closed shutting off the return circuit from the radiator and opening a by pass valve to admit coolant from a by pass pipe connected to the outlet housing on the rear of the engine Coolant exiting the cylinder heads meets a closed radiator circuit and is directed through four subsidiary circuits By Pass The greater proportion of flow is via the radiator by pass pipe b...

Page 211: ...that the cooling system remains fully filled whilst providing expansion space for the hot coolant and to facilitate topping up of the system a translucent header tank is mounted at the LH rear of the engine bay The tank is connected into the cooling system via a hose which joins into the heater return hose whilst an air bleed hose from the radiator feed hose near the outlet housing connects to the...

Page 212: ...osion protection The simplest means of checking the antifreeze concentration is to measure the specific gravity density of the coolant at a known temperature using a hydrometer The following table provides a general guide Density Concentration 20 C 60 C 25 1 039 1 020 33 1 057 1 034 50 1 080 1 057 The coolant density reflects the effective level of mono ethylene glycol and not the level of corrosi...

Page 213: ... and a spigot at the top of each sideframe with each spigot engaging into a rubber mounting grommet contained in a bracket bolted to the subframe Radiator Fans Mounting rails for the cooling fan cowling run across the top and bottom of the rear face of the radiator being secured by screws to the radiator sideframes with forward extensions to carry the a c condenser by a single screw at each corner...

Page 214: ... signal voltage outside of the acceptable range a default setting equating to 60 C will be substituted and the cooling fans will run at half speed Re circulation Pump A coolant re circulation electric pump is mounted on a bracket fixed to the underside of the intake airbox and is plumbed into the heater supply line close to the coolant outlet housing at the LH end of the engine When energised the ...

Page 215: ... appropriate wheelarch liner removed Replacement of a sill pipe is not possible without removing or cutting the body sill which is bonded to the chassis Such a pipe replacement should not however be necessary unless accident damaged together with the body sill For full access to the wheelarch area pipes the front clamshell must be removed ...

Page 216: ... Section LN FUEL SYSTEM SECTION LN Sub Section Page General Description LN 1 3 Fuel Requirement Filling LN 2 4 Precautions LN 3 5 Fuel Pump Sender Assembly LN 4 6 Fuel Tank LN 5 7 Fuel Supply Test LN 6 8 Charcoal Canister LN 7 8 ...

Page 217: ...or valve Push fit Filler neck Fuel rails connector Throttle body Fuel injector Purge solenoid valve Test port Charcoal canister Fuel tank Fresh air vent purge air intake Tank breather pipe Push fit Tank pressure connector sensor Pump sender unit L67 Fuel feed pipe Tank mounting cradle ...

Page 218: ...amber incorpo rated into the housing of the pump sender unit After the filter a pressure regulating valve controls the output line pressure to around 3 2 bar spilling excess fuel back into the tank and supplying the pressurised fuel to the outlet port on the top surface A non recirculation type of fuel feed system is employed in order to minimise evaporative emissions The feed pipe is routed along...

Page 219: ...uel system damage and running problems resulting from the use of incorrect fuels will not be covered by your New Vehicle Warranty DO NOT push or tow start the car or turn off the ignition at engine speeds above idle or run the fuel tank dry Any of these actions may damage the catalytic converters Ethanol E5 E10 Amixture of 5 or 10 ethanol grain alcohol and unleaded petrol may be used in the Evora ...

Page 220: ...ote The remaining balance of approx 5 litres should be treated only as an emergency contingent the use of which may entail intermittent fuel starvation dependent on driving conditions and potential engine damage In such a situation driving style should be modified to minimise engine load and cornering forces If maximum engine or handling performance is to be exploited or severe gradients tackled a...

Page 221: ... the pressurised fuel to the outlet port on the top surface A non recirculation type of fuel feed system is employed in order to minimise evaporative emissions Note that for some markets a fuel tank pressure sensor for on board diagnostics is fitted alongside the pump sender in the tank top surface The fuel gauge sender is mounted on the side of the pump housing and uses a float on a pivoted arm t...

Page 222: ...refit This operation is most easily and safely performed when the fuel level is lowest If this is not possible it is recommended to pump out the fuel into a suitable container in order to minimise the tank weight 1 De pressurise the fuel system see sub section LN 3 2 Top connections Remove the cabin rear compartment floor trim Remove the central access panel and disconnect the fuel feed pipe and h...

Page 223: ...ge the sender mounting bracket from the canister Disconnect the electrical cables from the unit and withdraw Take care not to damage the float arm 4 For access to the pump depress the three retaining barbs and withdraw the reservoir canister from the pump assembly Unplug the pump electrical connector and pull the pump from its outlet spigot 5 Thoroughly clean the fuel inlet strainer socks on the p...

Page 224: ...nstream of the throttle valve The solenoid valve is opened during certain engine running conditions in order to allow in take depression to draw fresh air through the vent pipe and charcoal bed cleansing the charcoal of fuel before consuming the resultant vapour in the normal combustion process In this way the charcoal is prepared for further vapour absorption when the engine is stopped Control Sy...

Page 225: ... Windows MR 3 7 Door Mirrors MR 4 8 Switches Instruments Driver s Information MR 5 10 Component Location Fuse Ratings MR 6 23 Audio Equipment MR 7 27 Battery Battery Cables Earthing Points MR 8 28 Wiper Mechanism MR 9 29 Harness Routing MR 10 30 Headlamp Assemblies MR 11 31 Bulb Replacement MR 12 32 Instrument Panel MR 13 33 Circuit Diagrams MR 14 34 ...

Page 226: ...h doors and the tailgate Selectable cockpit intrusion detection using a microwave sensor Self powered siren to maintain protection if the vehicle battery is disconnected Personal protection by on demand activation of the siren Emergency alarm override and transmitter key programming using an alarm sPecific Identification Number PIN Homesafe and selectable dynamic drive away locking Transmitter Key...

Page 227: ...stem is armed when a door is not fully shut three triple beeps will sound as a warning and the doors will not be locked Opening a door will not trigger the alarm ii If the system is armed when the tailgate is not fully closed three warning double beeps will be heard and the doors will not be locked Opening a door in this instance will trigger the alarm When fully armed and after the settling perio...

Page 228: ...ey Battery Replacement The transmitter fobs will normally operate within a range of 5 metres from the car but this may be reduced by the presence of other radio signals in the vicinity The transmitters are powered by a long life 3V Lithium battery type CR2025 readily available from electri cal outlets which with normal use should last for 3 years To ensure continuity of operation it is recommended...

Page 229: ...ll transmitters have been programmed wait for 10 seconds or turn off the ignition To disable a lost or stolen transmitter from the system use the above procedure to programme 6 trans mitters if necessary repeatedly reprogramming the same transmitter if less than 6 programmed transmitters are to be used Disconnecting the Car Battery In order to prevent the alarm being triggered before disconnecting...

Page 230: ...unlock the doors from outside press the central unlock button on the transmitter key The first press will unlock just the driver s door Press a second time to unlock the passenger s door When the door is opened a fully closed window will drop slightly preparatory to easing its subsequent closing and the interior and footwell will be illuminated If the driver s door is opened whilst the ignition is...

Page 231: ...arm the alarm system When locking both doors by pressing down the sill buttons be aware of the potential for inadvertently locking the keys in the vehicle Inertia Switch The safety inertia switch is designed to operate on impact typified by vehicle collision to switch off the fuel pump and thus minimise any fire hazard The central door locking will also be triggered to unlock the doors The inertia...

Page 232: ...ex to provide a wider field of vision but by so doing make objects seem smaller and farther away than when viewed through a flat glass Take care when judging distances and approach speeds until familiarity has been gained Fold flat if fitted If necessary to reduce obstruction when parked both mirrors may be folded flat against the doors turn the ignition key to position l or ll select the central ...

Page 233: ...Page 9 Lotus Service Notes Section MR Blank page ...

Page 234: ... remaining electrical systems note that some circuits require the engine to be running lll Turning further clockwise to III against spring pressure will operate the starter motor As soon as the en gine starts allow the key to return to position II For the correct starting procedure see the later chapter Starting Procedure Running In To stop the engine turn the key back to I Note that in order not ...

Page 235: ...um engine speed is being approached No bulb test function applies Maximum engine speed is governed for both the continuous and transient during acceleration states and are detailed in the later section Tachometer As the rate of rpm increase is potentially greater in the lower gears the tell tale trigger points are tailored to accommodate the reaction time available As maximum rpm is approached the...

Page 236: ...following ignition switch on i If the MIL lights continuously whilst driving immediately reduce speed and adopt a moderate driving style Seek dealer advice without delay and avoid all unnecessary journeys ii If the MIL flashes an engine misfire has been detected which is likely to cause overheat damage to the catalytic converters Slow down immediately and be prepared to stop If the MIL then stops ...

Page 237: ...he parking brake released if the tell tale should light at any time after the 3 second check period stop the car immediately as the circuit has detected a dangerously low level of brake fluid in the master cylinder reservoir possibly caused by a hydraulic leak in one of the separate front or rear brake circuits In the event of a leak there is a danger that air may enter the hydraulic system and ca...

Page 238: ...p phase and once normal running temperature has been reached limits continuous engine speed to 6 600 rpm or 7 000 rpm in Sport mode During maximum acceleration through the lower gears very short bursts up to 6 800 rpm are allowed or 7 200 rpm in Sport mode Each time the ignition is switched on a re setting routine will be performed with the pointer sweeping to full scale and back to zero The scale...

Page 239: ...is shown on the instrument panel left hand screen whenever the ignition is switched on with units displayed in degrees Centigrade or Fahrenheit dependent on market The sensor is mounted by a grommet into the RH side of the engine radiator air intake duct If the temperature drops to 4 C 39 F or below the display will flash for ten seconds accompanied by a single audible chime to alert the driver to...

Page 240: ... to those of the analogue instrument Trip distance The Trip Distance Range and Average Fuel Consumption can all be reset by selecting that function and then pressing the info switch for more than one second until the display zeroes Coolant Temperature Display An indication of the engine coolant temperature is displayed with ignition on in the form of a vertical bar graph in the instrument panel ri...

Page 241: ...rent wheel position the TPMS will automatically identify the new configuration Note that the pressure sensors are powered by integral batteries with an average service life of 10 years It is recommended to renew all pressure sensors at this time interval Door Tailgate Open Display The instrument cluster right hand screen includes a plan view silhouette of the car which will graphically show when e...

Page 242: ...witched on Note that in order to cover the whole width of the car the view will be distorted from a conventional image Take time to familiarise yourself with the image displayed the parking aid beeping frequency and the actual distance being detected before fully utilising these systems Hazard Warning Lamps Switch The hazard warning switch button is located inboard of the audio set and is backlit ...

Page 243: ... beams Note that with ignition on the main beam tell tale in the instrument panel will indicate the current status Info Button Momentarily pressing the Info button on the end of the stalk will scroll through a menu of trip functions see above Windscreen Wiper Washer Control The right hand lever switch is enabled at ignition key positions I and II and is operated as follows Wiper functions To flick...

Page 244: ...t the end of the passenger fascia accessible only with the door open and is operated using the me chanical ignition key insert the key and turn clockwise to the OFF position and withdraw the key With the ignition switched on a tell tale lamp in the instrument panel will light up amber as a reminder that the passenger airbag has been disabled To reinstate airbag opera tion insert the key in the PAB...

Page 245: ... fascia outboard of the steering column and is operative only with the ignition on To switch off LTC hold the button pressed for one second until the button surround lights up in conjunc tion with the amber LTC off tell tale in the instrument panel WARNING Lotus Traction Control should always be active when driving on the public highway in normal conditions If the system is switched off when drivi...

Page 246: ... set speed will be maintained road gradient and winds permitting The accelera tor may be used to increase speed temporarily without affecting the setting Note The system cannot be activated below 20 mph 32 km h or above 125 mph 200 km h Deactivation Cruise control will be deactivated when any of the following actions occur The brake pedal is depressed The clutch pedal is depressed The on off cance...

Page 247: ...orn C2 5A Battery services C3 5A Alarm B C4 20A Rad fan relay 1 C5 20A Rad fan relay 3 C6 10A Radio B C7 5A Key in relay C8 2A Ignition switch C9 15A Driver s window C10 15A Pass window C11 7 5A Hazard Turn C12 3A Interior lighting C13 20A Int control mod C14 C15 5A LH sidelamps C16 5A RH sidelamps C17 15A LH headlamp C18 15A RH headlamp C19 15A Main beam C20 3A Rear foglamp Slot Rate Circuit C21 ...

Page 248: ...rated Control Module Also mounted on the front fusebox panel is the integrated control module ICM which is used to perform switching and control functions for many of the circuits The module uses 4 harness connector blocks designated A B C D with all connection details identified on the relevant circuit diagram and summarised below 13 1 8 1 6 1 11 1 A B C D 26 14 16 9 12 7 22 12 m268 ...

Page 249: ...t switch input B8 Driver door switch input B9 CDL switch illumination B10 CDL switch monitor B11 Lock status input B12 Unlock status input B13 B14 Passenger door switch input B15 Headlamp switch input B16 Sidelamps switch input Pin Description C1 Main beam flash power input C2 Int fan fast input C3 Fog switch illum input C4 C5 Drive away locking output C6 Sidelights switch illum output C7 HRS outp...

Page 250: ...box Two maxi fuses protecting major circuits are also provided along with four single contact change over micro relays and two power relays Fuse colours 2A Black 5A Orange 15A Light blue 3A Violet 7 5A Brown 20A Yellow 4A Pink 10A Red 25A Clear Slot Rate Circuit R1 10A ECU fan relay 3 R2 7 5A Injectors R3 10A Ignition coils R4 2A Re circ pump R5 R6 R7 5A ECU ignition R8 7 5A Engine solenoids R9 5A...

Page 251: ... CD audio DVD video operable only with the parking brake engaged i pod to i pod video interaction control MP3 player Satellite navigation Integrated microphone for Bluetooth phone operation When set is switched on automatic display from reversing camera when reverse gear is engaged Note that the screen should be cleaned occasionally with a lint free spectacle polishing cloth Note The satnav system...

Page 252: ...tted with security coded audio equipment check that the code is available for entering after battery reconnection ii Wait for at least ten seconds after switching off the ignition to allow the engine management system to adjust the setting of some components ready for re starting iii Ensure that all electrical loads e g lights are switched off iiv Check that the security alarm is disarmed If the b...

Page 253: ...ifficulties may be encountered If current drain is found to significantly exceed specification the cause must be established by isolating components e g at fusebox and rectifying faults as necessary Battery Cables Two red cables are connected to the battery positive post One leads to the solenoid on the starter motor A second cable leads to the positive post fixed to the back of the cabin bulhead ...

Page 254: ...senger side and through to the top of the scuttle Then it runs across the full width of the scuttle to supply all the fascia components and to each of the separate door harnesses At the centre of the front bulkhead a branch of the main harness penetrates the bulkhead and di vides along each side to supply the HVAC functions ABS lighting and other front mounted electrical equipment From the same ju...

Page 255: ...rated the headlamp washer pump is also activated for 2 seconds the pressure from which causes the telescopic washer module to extend about 20 mm above the headlamp cover and deploy two conical sprays of fluid from a pair of high flow jets The module then returns under spring action to its flush position Note that certain atmospheric conditions may result in some condensation inside the lamp unit T...

Page 256: ...eelarch liner mr 12 bulb replacement Headlamp Units Halogen Headlamps if fitted On cars fitted with halogen headlamp assemblies the lamps are fitted in the same housings as used for the HID headlamps Remove the access cover in the wheelarch liner and pull off the protective boot from the back of the headlamp housing Pull the harness plug off the bulb release the spring wire retaining clip and with...

Page 257: ...ing the harness connector Side Repeater Lamps The side repeater lamps are mounted in the front clamshell behind each wheelarch and use durable light emitting diodes LEDs The lamps are servicable only by complete replacement the lamp being secured by an adhesive gasket Licence Plate Lamps To replace a bulb in a rear licence plate lamp first remove the two screws securing the lamp to the body and wi...

Page 258: ...ensors C9 55 EMS Cruise Control C10 56 Sidelamps D1A 57 Switch Illumination D1B 58 Headlamps Xenon D2A 59 Headlamps Halogen D2B 60 Rear Fog Lamps D3 61 Direction Indicators Hazard Lamps D4 62 Brake Lamps D5 63 Reverse Lamps Reversing Camera Sensors D6 64 Interior Lighting LHD D7A 65 Interior Lighting RHD D7B 66 Airbags E1 67 Anti Lock Brakes Traction Control Sport Mode E2 68 Instrument Cluster E3 ...

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Page 308: ...ge 1 Lotus Service Notes Section OK MAINTENANCE LUBRICATION SECTION OK Page Recommended Lubricants 2 Maintenance Schedule 4 Pre Delivery Inspection 7 Pre Delivery Paint Mark Up 9 Licence Plate Fitment 10 ...

Page 309: ...g and fuel economy at low temperatures in combination with good wear protection at elevated temperatures and at high engine speeds Note that no oil additives are approved by Lotus Viscosity ambient above 20 C SAE 5W 40 Quality standard API SL CF ACEA A3 B3 04 Capacity refill inc filter 6 1 litre dry no heat exchanger 6 8 litre dry with heat exchanger 7 1 litre Difference between high low dipstick ...

Page 310: ...y areas e g on unmetalled roads Change the oil and filter as soon as possible after driv ing in a dust storm Stop start driving with frequent short trips where the engine rarely warms up thoroughly especially in cold weather climates and or frequent or prolonged idling Track use with repeated high rpm wide throttle openings and high oil temperatures In these circumstances individual judgement must...

Page 311: ... 3 Inspect brake pads discs 4 500 m 7 500 km intervals or as required 4 Thorough safety check including wheels tyres suspension steering and brake systems 5 The Evora is intended for use as a road going passenger vehicle IT IS NOT DESIGNED OR INTENDED FOR USE OFF ROAD INCLUDING ON CLOSED CIRCUIT TRACKS OR FOR USE IN A COMPETITIVE MANNER INCLUDING TIMED LAPS OR RUNS ANY SUCH USE WILL INVALIDATE THE...

Page 312: ...l cndts 17a Inspect brake pad thickness disc condition special cndts 18 Inspect brake hoses pipes hydraulic units 19 Check brake fluid level X 20 Renew brake clutch fluid Steering Suspension 21 Check security and condition of front rear suspension 22 Inspect dampers for leaks and performance 23 Inspect front and rear wheel bearings for play 24 Inspect condition of drive shaft gaiters 25 Inspect st...

Page 313: ...e suspension noise vibration Wheel balance Recommended Service Times After Sales Service 1 9 hr Regular Service 2 8 hr Op 2a 0 6 hr Op 4 0 4 hr Op 5a 0 1 hr Op 6a 0 7 hr Op 7 0 6 hr Op 15 1 0 hr Op 17a 0 1 hr Op 20 0 6 hr Op 33 0 1 hr Op 34 0 1 hr General comments Additional Work Performed or Required Work completed by Owner s Maintenance Booklet stamped Dealer Stamp Date ...

Page 314: ...partment Check security of battery terminals and voltage Below 12 4V recharge Below 11 7V replace Inspect operation of all exterior interior lamps Inspect operation of horn hazard switch Inspect operation of alarm system CDL fuel flap release Inspect wiper operation at all speeds park position Inspect screen washer powerwash operation jet alignment reservoir level Inspect operation of all instrume...

Page 315: ...y claims on the particular car being rejected ONCE COMPLETED SEND ORIGINAL COPY OF PDI FORM OWNER S HANDBOOK MAINTENANCE RECORD PAGES P D I REGISTRATION OF SALE AND NEW CAR HANDOVER CHECKLIST LSL486 TO Pre Delivery Inspection Completed by Date Undertake complete vehicle valet Valet Brake performance Additional Work Completed by Road Test Performance Check Add comments as necessary Engine performan...

Page 316: ...G N SHADING C CHIPS O OVERSPRAY D DISTORTION P PRE RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES H PIN HOLES T THIN PAINT K SINKAGE U M MAT CREASES V VOIDS DATE OF PDI VIN COLOUR OWNER PRE DELIVERY PAINT MARK UP EVORA PAINT DEFECT CODE DIRT UNDER PAINT ...

Page 317: ... screws with suitable blind fix nuts e g Rawlnuts The plate should be aligned with the bottom edge of the plinth to reduce potential damage from grounding or kerbs whilst providing the minimum restriction to radiator airflow Rear The rear licence plate should be mounted on the surface of the rear transom recess using double sided tape and or fixing screws at the dealer s customer s discretion Ensu...

Page 318: ...Heater A C Airflow Overview PN 2 5 Cooling Fans Re circulation Pump PN 3 9 Refrigerant Handling PN 4 10 Refrigerant Pipework Precautions PN 5 10 Refrigerant Oil PN 6 12 Compressor PN 7 12 Condenser PN 8 14 Receiver Drier PN 9 15 Heater Evaporator Fan HVAC Unit PN 10 15 Air Distribution Unit ADU PN 11 16 Refrigerant Pipes PN 12 17 ...

Page 319: ...essure vapour line Receiver drier Condenser Evaporator Low pressure vapour line Compressor p115 Heater Circuit Heater matrix Heater Thermostat return rail housing Header Coolant outlet tank housing Air bleed screws Outlet from head Re circulation pump Pipe runs through LH sill p116 ...

Page 320: ...en by multi vee belt from the front end of the crankshaft via an electromagnetic clutch a condenser fixed to the front of the engine cooling radiator between the front subframe longerons and tilted forwards at 45 an evaporator unit cooler contained within the HVAC housing ahead of the cabin footwell bulkhead a thermostatic expansion valve fitted at the inlet connection to the evaporator a refriger...

Page 321: ...ary switch see below Hot refrigerant vapour from the compressor is fed via flexible hoses and alloy pipwork routed through the body RH sill to the front mounted condenser Condenser The aluminium condenser is a parallel flow heat exchanger configured with side mounted collector tanks interconnected by 40 oval shaped horizontal tubes all provided with generous finning The unit is fixed to the front ...

Page 322: ...the evaporator via the expansion valve block into which they are sealed using O rings and a clamp plate The inlet is supplied from the receiver drier and the outlet feeds into pipework routed through the body RH sill to the compressor Ventilation Air in the cabin is exhausted via an outlet vent at the left hand side of the rear bulkhead and another at the bottom right hand corner of the bulkhead D...

Page 323: ...k on a horizontal axis controls the airflow exiting the ADU into a top mounted port for the windscreen vents an adjacent port for the face level vents and via a port in each end plate of the mask to outlets supplying a duct in the top of the passenger footwell and through the inboard side of the pedal box The rotation of the mask is driven by a stepper motor common with the air intake and air blen...

Page 324: ...ll vents Footwells windscreen To face level vent ducting in underside of fascia top panel Airflow from HVAC unit To footwell vents Airflow from HVAC unit To footwell vents To windscreen vent ducting in underside of fascia top panel Airflow from HVAC unit To footwell vents ...

Page 325: ...rated into the bottom of the HVAC housing is always from the cabin interior The fresh air intake on the top of the unit is controlled by a stepper motor and flap valve and is normally open to provide approximately 30 fresh airflow To close the intake and prevent fumes being drawn into the cabin or to provide the quickest response to temperature change requests the fresh air intake may be closed of...

Page 326: ...ic converter at the rear of the engine bay PN 3 COOLING FANS RE CIRCULATION PUMP The two cooling fans are fitted on the top side of the radiator condenser package and the coolant re circulation pump is mounted at the LH side of the engine bay beneath the air cleaner Both the fans and pump are controlled by the engine management ECU using data provided by the engine coolant temperature sensor and t...

Page 327: ...pour line port is fitted in the pipe between the evaporator and compressor the high pressure liquid line port is fitted in the pipe between the compressor and condenser 3 Heavy concentrations of refrigerant vapour can produce toxic gas if exposed to a naked flame The gas can also attack metal 4 Refrigerant drums must never be left open always ensure the caps are securely fitted 5 Never transport d...

Page 328: ... exp valve 1 M6 1 0 9 Nm 10 Clamp plate expansion valve to evap 1 M5 0 8 6 Nm 11 Evaporator to sill pipe 1 1 1 16 14 UNS 1 8 35 40 Nm Use refrigeration oil only smear on O rings and threads prior to assembly Gloves should be worn when handling refrigeration oil see data sheet Key Description Diameter Part Number A Suction line to compressor Condenser connections 16 mm A120P6002H B High pressure li...

Page 329: ...g amount of new oil must be added to the system on re assembly Condenser 30 cm Evaporator 30 cm Any major pipe or hose 10 cm Receiver drier 30 cm Approved Oils Use only Denso ND OIL 8 low viscosity ISO46 PAG oil or equivalent Sanden SP10 Four Seasons 59007 Refrigerant oil absorbs water and should not be exposed to the atmosphere for any longer than is strictly necessary to perform the operation Ne...

Page 330: ...frigerant oil will have been lost Drain the remaining oil from the compressor by removing the drain plug and rotating the clutch plate Add 150 cm of new refrigerant oil see above to the compressor before refitment Fitting New Compressor New compressors are sealed and pressurised with nitrogen gas The sealing caps should be removed only immediately prior to compressor fitment at which time the gas ...

Page 331: ...ut disturbing the engine radiator and is facilitated by removal of the front clamshell but is also possible with this panel in situ using access provided by the headlamp apertures To Remove Condenser 1 Remove the RHF wheelarch liner and recover the refrigerant using equipment connected to the service ports at the rear of the wheelarch 3 Remove the front undertray and both headlamp assemblies see s...

Page 332: ...matrix The complete HVAC unit is mounted between the chassis front bulkhead and subframe cross member with the steering rack beneath and the radiator air outlet duct ahead To Remove HVAC Unit 1 Remove the front undertray front clamshell radiator air outlet ducts and HVAC air inlet duct 2 Remove the wiper motor mechanism from the windscreen surround 3 Recover the refrigerant 4 Remove the HVAC polle...

Page 333: ...wiched between the underside of the fascia top demist duct and the chassis The unit comprises several plastic mouldings bonded and rivetted together to contain the rotary distribution drum which controls the airflow to the windscreen face level vents and footwells The stepper motor for the drum is mounted on the left hand side of the unit To Remove the Air Distribution Unit 1 Remove the main fasci...

Page 334: ... and expansion valve take the form of aluminium pipes clamped along the outside of the chassis RH siderail such that removal of the body side panel is required for access to the pipes Replacement of the pipes is unlikely to be necessary other than as a result of accident damage in which case the body sill will be replaced in accordance with Service Notes sub section BS 9 ...

Page 335: ... Lotus Service Notes Section QJ Page 1 CLUTCH SECTION QJ Sub Section Page General Description QJ 1 3 Clutch Pedal QJ 2 3 Hydraulic Release System QJ 3 3 Clutch Assembly QJ 4 5 ...

Page 336: ...Page 2 Lotus Service Notes Section QJ GENERAL LAYOUT Illustration TBA ...

Page 337: ...inder piston is pushed progressively further back on the return stroke with a corresponding rise in the reservoir fluid level QJ 2 CLUTCH PEDAL The clutch pedal is fabricated from steel plate and features synthetic top hat bushes for maintenance free articulation on the steel pivot shaft and a serrated alloy footpad A hollow steel pivot shaft serving the brake and clutch pedals is bolted to a stee...

Page 338: ...nd withdraw the cylinder If necessary remover the cylinder end protective rubber boot and pushrod and use compressed air in the hydraulic port to expel the piston as sembly To re assemble coat the seals with lithium soap base glycol grease before inserting into the cylinder and then fitting the pushrod and boot Secure with the two M8 bolts tightened to 12 Nm 9 lbf ft connect the hydraulic line 15 ...

Page 339: ...ed or if addressing symptoms of clutch judder renew the friction plate 3 Release bearing fork Unclip the release bearing from the fork and check the bearing for discernible play noise or rough feeling and renew if there is any doubt Check the arm for undue wear on any of the contact surfaces and for cracks Check the release fork pivot ball 4 Flywheel Check the friction surface of the flywheel for ...

Page 340: ...age 1 Lotus Service Notes Section TDT TECHNICAL DATA ENGINE SECTION TDT Page General 2 Cylinder Block 2 Cylinder Head 2 Valves Springs 3 Camshafts 3 Pistons 3 Crankshaft 3 Oil Pump 3 Coolant Thermostat 4 ...

Page 341: ...ine management Lotus T4e controller Ignition system Direct ignition using individual plug top coils Fuel system Port injection Sychronous and non synchronous operation Hot wire airflow sensor Fuel requirement Minimum 95 RON Intake system Single throttle valve 2 stage intake tract length Maximum continuous engine speed std 6 600 rpm Sport mode 7 000 rpm Maximum transient engine speed std 6 800 rpm ...

Page 342: ...in camshafts Endfloat std 0 08 to 0 13 mm 0 0031 to 0 0051 in service limit 0 15 mm 0 006 in Maximum oil clearance front journal 0 15 mm 0 006 in except front 0 09 mm 0 0035 in pistons Diameter 10mm below pin centreline std 93 960 to 93 980 mm 3 6992 to 3 6999 in miniumum 93 830 mm 3 6941 in Bore oil clearance std 0 020 to 0 052 mm 0 0007 to 0 0020 in service limit 0 060 mm 0 0024 in Gudgeon pin o...

Page 343: ... Lotus Service Notes Section TDT Page 4 coolant thermostat Valve opening temperature 80 to 84 C 176 to 183 F Valve lift at 95 C 10 mm ...

Page 344: ...rvice Notes Section TDU TECHNICAL DATA VEHICLE SECTION TDU Page Dimensions 2 Capacities 2 Wheels Tyres 2 Front Suspension 3 Rear Suspension 3 Electrical 3 Transmission 4 Clutch 4 Brakes 4 Steering 4 Fuel Consumption 4 ...

Page 345: ...t exchanger 6 1 litre High low dipstick mark difference 1 0 litre Transmission oil 2 3 litre Brake system hydraulic fluid 450 cc Clutch system hydraulic fluid 130 cc Fuel tank 60 litre Coolant 17 litre Refrigerant 0 625 kg WHEELS TYRES Tyres normal use Type Pirelli P Zero Size front 225 40 ZR18 rear 255 35 ZR19 96Y Pressure cold front 2 3 bar 33 5 psi rear 2 5 bar 36 psi Winter Tyres Type Yokohama...

Page 346: ...al REAR SUSPENSION Type Independent Upper and lower lightweight forged alloy wishbones co axial coil spring telescopic damper unit tubular anti roll bar Geometry Mid laden ride height 2 x 75 kg occupants full fuel tank set car to this height before measuring geometry front 125 mm below front end of chassis siderail rear 147 mm below rear end of chassis siderail Camber optimum 1 6 tolerance range 1...

Page 347: ...ckness new 8 0 mm Damper springs 4 off Hub material Sintered steel Clamp load new 8350N BRAKES Brake discs Cast iron curved vane ventilated cross drilled Rear discs incorporate parking drums Disc dimensions front 350 x 32 mm rear 332 x 26 mm 185 mm drum Callipers A P Racing aluminium alloy body 4 pistons in opposed pairs Common casting front rear Piston size front Leading 38 1 mm Trailing 41 3 mm ...

Page 348: ...ts VE 3 4 Door Sill Trim Panel VE 4 4 Lower A Post Trim Panel VE 5 5 Centre Console VE 6 5 Fascia Dash Panel VE 7 5 Fascia Lower Panels VE 8 6 Main Fascia Panel VE 9 6 Steering Column Shroud VE 10 6 Windscreen Pillar Trim Panels VE 11 7 Rear Quarter Panels VE 12 7 Rear Seat Backrest or Bulkhead Pad VE 13 7 Rear Window Surround VE 14 8 Roof Lining VE 15 8 ...

Page 349: ...ill panel Instrument cowl top access cover Fascia top panel Airbag cover Fascia dash panel Outboard switch panel Column shrouds Inboard switch panel Steering column infill panel Fascia panel lower centre Fascia panel lower right Fascia end pl1405 closing panel ...

Page 350: ...Fascia panel lower left hand and right hand Fascia dash panel 2 Polyurethane Foam Panels include Fascia top panel Passenger airbag cover Driver s side fascia infill panel Glovebox lid Steering column cover 3 Reaction Transfer Compression RTC moulding using a polypropylene glass reinforced moulding to which is bonded a Nylon polypropylene fabric with a foam backing visible surface and a polypropyle...

Page 351: ... Face level vent release handle escutcheon 1 The face level vent itself may be pulled out of the escutcheon with the door panel in situ 2 To remove the escutcheon the door panel must be removed Then from behind the panel remove the blanking sticker on the air duct moulding to access the two screws securing the front of the escutcheon and release another pair of screws in the door release handle br...

Page 352: ... console top panel and pull the rear part of the panel upwards to withdraw the two Tower clips 7 Remove the 4 screws securing the top surfaces of the console sides together Remove the 3 screws securing each of the side s lower rear flanges to the floor channel Pull away the front end of each side panel to release the two spring steel clips ve 7 Fascia Dash panel The fascia dash panel reaches acros...

Page 353: ... underside of the fascia 3 Withdraw the column infill panel or glovebox from the location pin 4 Central fascia lower panel First remove the centre console see section VE 5 Remove the two screws securing the centre fascia lower panel to the scuttle beam and the two screws to the underside of the main fascia panel ve 9 Main Fascia panel The main fascia panel extends from the base of the windscreen t...

Page 354: ...he two screws from the base of the panel and the two at the upper rear edge Pull the panel from its two spring clips around the window and feed the seat belt through the panel aper ture VE 13 rear seat backrest or bulkhead pad On 2 2 cars the rear seat backrest is secured by a screw behind each backrest top insert pad two screws at the bottom edge and Velcro patches To remove the seat Remove the r...

Page 355: ... at the rear edge To remove the roof lining panel Pull the rear window surround from its 4 spring clips and remove the two screws at the rear edge of the roof lining Release the seat belt upper anchorage from the B pillar and remove the B post upper trim Prise out the fir tree button from the base of each windscreen pillar trim and pull each trim panel from its three spring clips Remove the three ...

Page 356: ... Tale WF 2 3 Data Link Connector WF 3 4 Trouble Codes WF 4 4 Lotus TechCentre WF 5 4 Safety Precautions Shipping Storage Disposal WF 6 5 Theory of Operation WF 7 7 Sensor Diagnostic Module SDM WF 8 9 Driver Airbag Module WF 9 10 Rotary Connector WF 10 11 Passenger Airbag Module WF 11 12 Seat Belt Pre tensioners WF 12 13 ...

Page 357: ...Page 2 Lotus Service Notes Section WF Illustration to follow ...

Page 358: ...lmost immediately by triggering of the second stage too late to affect the speed of airbag inflation but ensuring that the airbag is then dead and in a stable condition Initiated at the same time as the airbags is a pyrotechnic device on each front seat belt reel assembly which uses rapid gas generation and a train of balls in a track to apply a tightening force to the belt reel and remove any sla...

Page 359: ...OM and are not cleared if the battery is disconnected Vehicle crash data is also stored in coded form in the SDM and is not erasable New SDMs are supplied only against V I N and on exchange with the old unit WF 5 LOTUS TECHCENTRE CAN BUS Diagnostics ControllerArea Network CAN is an electronic standard to allow high speed communication between modules and controllers via a serial data BUS The BUS i...

Page 360: ...airbag module or SDM boxes more than two high Always store and handle airbag modules and SDMs in an upright position Never store SDMs upside down Sensor Diagnostic Module SDM Forward Crash Sensors The SDM and forward crash sensors are calibrated specifically to the Evora and are mounted in a dedicated manner in specific positions Never use SRS components from any other vehicle or modify their moun...

Page 361: ...use channels The undeployed inflator module contains substances that can cause severe illness or personal injury if the sealed container is damaged during disposal Disposal in any manner inconsistent with proper procedures may be a violation of federal state and or local laws Reference should be made to the local State authority for the correct disposal procedures for deployed inflator modules Veh...

Page 362: ... not attempt to repair the steering column or chassis or any of the above mentioned components Service only by replacement WARNING Proper operation of the SRS system requires that any repairs to the vehicle structure return it to its original production configuration Deployment or any visible damage to the SRS components and or their respective mounting brackets requires replacement not repair WF ...

Page 363: ...ndition monitoring by the safing sensor occurs in addition to and independent of the crash algorithm Note that neither the seat belt pre tensioners nor the airbags will be activated by the SDM as long as the diagnostic mode is active Fault Display The following conditions lead to a fault display in the form of continuous illumination of the airbag tell tale One or more trouble codes requiring tell...

Page 364: ...of seat belt pre tensioners min 10 0 V max 16 0 V Energy Reserve Energy reserve capacitors within the SDM are provided to allow SRS deployment if the vehicle battery power supply is interrupted during the time of vehicle impact The capacitors provide full support of the accel eration sensing and airbag initiation capability for a minimum of 150 ms after a loss of external power supply provided tha...

Page 365: ...ach of the two connector sockets on the rotary connector one connector for each airbag stage The shorting bar operates when the connector is unplugged to short across the feed and return connections to the airbag Thus if a positive feed or earth is inadvertently applied to the connector terminals both sides of the inflator module will be subject to the same electrical po tential and no deployment ...

Page 366: ...nnections to the inflator module Thus if a positive feed or earth is inadvertently applied to the connector terminals both sides of the inflator module will be subject to the same potential and no deployment will occur When servicing the rotary connector it is most important that the correct orientation of the connector is maintained on refitment or the connector will run out of travel and be brok...

Page 367: ...edures must be followed in the order listed to temporarily disable the airbag system whilst working in the immediate vicinity of an airbag Failure to follow this procedure could cause unintended airbag deployment resulting in personal injury and unnecessary airbag sys tem repairs i Turn off the ignition ii Before disconnecting the battery use the Lotus TechCentre to read any stored trouble codes i...

Page 368: ...ELT PRE TENSIONERS WARNING Failure to comply with the instructions safety standards and operating procedures as described in this section may cause vehicle damage and or personal injury Both driver and passenger front seat belt assemblies must be replaced after SRS deployment Do not attempt to repair or reuse Device Operation Initiated at the same time as the airbags is a pyrotechnic device on eac...

Page 369: ... the pyrotechnic charge small gas quantities are developed The main constituent of the gases is Nitrogen Note This gas is not toxic The pre tensioner assemblies must be protected against exposure To temperatures over 90 C 195 F at contact with surfaces 90 C during 106 hrs From sparks and naked flames WARNING If exposed to temperatures in excess of 140 C self ignition of the pyrotechnic charge of t...

Page 370: ...fety glasses and vinylic or nitrylic protection gloves After handling a loaded pre tensioner wash hands with soap and water There is no danger of exposure to propellants in the sealed system The propellant mix is in a solid state therefore no inhalation is possible even if the gas generator cartridge is broken Avoid skin contact and do not ingest the propellant First aid Ingestion Help the person ...

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