Lotus Evora Service Notes

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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

Table of Contents

Summary of Contents for Lotus Evora

Page 1: Service Notes
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 This publication has been designed for use by Lotus Dealers familiar with general workshop safety pro- cedures and practices. Take all appropriate action to guard against injury to persons or damage to property. Lotus policy is one of continuous product improvement, and the right is reserved to alter specifications at any time without notice.
Page 3 Technical Data - Engine - Vehicle Chassis Bodycare & Repair Body Fittings Front Suspension Rear Suspension Engine & Engine Management - Lotus supplement - Toyota engine repair manual Engine Management Transmission - Lotus supplement - Toyota transmission manual Wheels & Tyres...
Page 4 (model year), and 14 to 17 (serial number) will be quoted. Assembly Plant H = Hethel Manufacturer Vehicle Type Check B = Shah Model Identifier Code 122 = Evora Digit Alam 4 = Evora S C C 1 2 3 6 7 8 14 15 16 17 Engine Type Restraint...
Page 5 Lotus Service Notes Introduction MODEL HISTORY Evora Introduction: First deliveries commence June 2009 at '09 VIN serial number 0721. Page 5...
Page 6 Note that in order fully to exploit the benefits of light weight, and to maximise stowage space, the Evora has no provision for spare wheel carriage or lifting jack. A temporary puncture recovery facility is provided in the form of a tyre inflator aerosol stowed in the right hand side of the boot.
Page 7 Lotus Service Notes Section AJ CHASSIS SECTION AJ Sub-Section Page General Description AJ.1 Chassis Straightness Check AJ.2 Rear Subframe AJ.3 Front Subframe AJ.4 Page 1...
Page 8 Lotus Service Notes Section AJ Page 2...
Page 9 Section AJ AJ.1 - GENERAL DESCRIPTION The chassis frame of the Lotus Eagle is constructed primarily from aluminium alloy extrusions and formed alloy sheet, with the various sections bonded together using an epoxy adhesive with secondary drive-in fasten- ers. The main chassis unit includes the passenger cell, footwells, front bulkhead, front scuttle with door hinge posts and the fuel tank bay.
Page 10 Lotus Service Notes Section AJ in significant bending, tearing or distortion of the aluminium structure, especially in respect of the attachment points for the front and rear subframes, the recommended repair is to renew the partial body assembly, which comprises the main chassis tub, with jig bonded composite rear bulkhead, body sills and windscreen frame.
Page 11 Lotus Service Notes Section AJ AJ.3 - REAR SUBFRAME The rear ends of the chassis siderails are linked by a fabricated sheet steel subframe which provides mountings for the powertrain, rear suspension, rear body, exhaust muffler and seat belt mounting frame struts.
Page 12 Lotus Service Notes Section AJ Re-assemble the subframe to the chassis using Duralac MSDS anti-corrosion compound (A111C6017S) between the mating faces and inserting the appropriate shim stacks. Fit all fixing bolts and tighten evenly and progressively to a final torque of 45 Nm.
Page 13 Lotus Service Notes Section AJ Page 7...
Page 14: Table Of Contents
Lotus Service Notes Section BU BODYCARE & REPAIR SECTION BU Sub-Section Page General Description BU.1 Lotus Composite Body Features BU.2 Bodycare BU.3 Accident Damage Assessment BU.4 Body Panel Bonding Materials BU.5 Replacement of Bonded-On Panels - General BU.6 Roof Panel BU.7...
Page 15 Lotus Service Notes Section BU Page 2...
Page 16 Section BU BU.1 - GENERAL DESCRIPTION The body panels of the Lotus Evora are constructed of composite materials, and contribute to the overall stiffness of the body/chassis structure. The panels are attached to the aluminium chassis and/or other body panels either by elastomeric polyurethane adhesive, where maximum structural integrity is required, or by threaded fasteners, where ease of service access and repair is the greater priority.
Page 17 Front and rear bumpers BU.3 - BODYCARE The acrylic enamel paint finish of the Evora is extremely resistant to all normal forms of atmospheric attack. Following the simple maintenance procedure summarised below will help retain the gloss, colour and protective properties of the paint throughout the life of the vehicle.
Page 18 Lotus Service Notes Section BU up liquid can contain corrosive salts, and will remove wax and accelerate oxidation). Frequent washing is the best safeguard against both seen and invisible contaminants. Wash in the shade, and use a cotton chenille wash mitt or a sponge rinsed frequently to minimise entrapment of dirt particles. Use a straight back and forth washing motion to avoid swirled micro scratches, and rinse thoroughly.
Page 19 Lotus part no. A082B6355V Adhesive: Betaseal 1701 Lotus part no. A082B6281 F Applicator Bottle An applicator bottle is available for use with some cleaners and primers, and has a disposable felt pad which should be changed regularly to minimise surface contamination:...
Page 20 Lotus Service Notes Section BU container. - Push the applicator head onto the bottle, and fit the felt pad. - Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides. - Wipe the pad over the substrate surface using minimal pressure to wet the surface.
Page 21: Bu.1
Lotus Service Notes Section BU Prior to decanting Betaprime 5500, shake the container for at least 60 seconds to disperse the solid content of the material into suspension. - Pour the primer into the applicator bottle and immediately replace the green cap.
Page 22: Bu.3
For repairs of cracked or damaged panels 'in-situ', plastic panel repair systems may be used such as Wurth Replast, available under Lotus part number T000T1469F. Full instructions are supplied with the kit. BU.6 - REPLACEMENT OF BONDED-ON PANELS - GENERAL Bonded body panels are secured using Dow Chemicals products ‘Betaseal’...
Page 23: Bu.4
Lotus Service Notes Section BU Prepare the bonding surface of the new roof panel with Betaclean 3900 and Betaprime 5404 (see sub- section BU.5). Prepare the surface of the residual adhesive on the body panels and seat belt frame using Betawipe 4000 (see sub-section BU.5).
Page 24: Bu.5
Lotus Service Notes Section BU 5404 (see sub-section BU.5). - Apply a bead of Betaseal 1701 adhesive (see sub-section BU.5) to the whole of the chassis bonding flange on the windscreen frame, and to the body side panel flanges. - Spring the body sides apart sufficiently to allow careful positioning of the windscreen frame onto the chassis and locate with the tie bracket to the pedal box.
Page 25 Lotus Service Notes Section BU RH side: - Engine radiator return pipe - A.C. feed and return pipes - PAS feed and return pipes - Right hand rear brake pipe LH side: - Engine radiator feed pipe - Heater feed and return pipes...
Page 26 Lotus Service Notes Section BU Bonding of rear bulkhead: The rear bulkhead panel is positioned by reference to the rear seat belt mounting frame, and should be fitted only as a jig built assembly of bulkhead and frame. Clean the mating surface on the bulkhead with Betaclean 3900 (black cap) and prime with Betaprime 5404 (red cap) or, where applicable, use Betawipe 4000 to re-activate old adhesive (refer to sub-section BU.5).
Page 27: Table Of Contents
Lotus Service Notes Section BV BODY FITTINGS SECTION BV Sub-Section Page General Overview Reservoir Access Hatch BV.1 Tailgate BV.2 'A' Panels BV.3 Front Clamshell BV.4 Front Bumper BV.5 Rear Clamshell BV.6 Rear Bumper BV.7 Door Mirrors BV.8 Door Shell, Beam & Hinges BV.9...
Page 28: Bv.7
Lotus Service Notes Section BV Page 2...
Page 29: Bu.8
Lotus Service Notes Section BV BV.1 - RESERVOIR ACCESS HATCH The Lotus Evora is fitted with a front hinged, composite, access hatch in the front body to provide ready access to the brake/clutch mas- ter cylinder reservoir and windscreen washer reservoir filler neck.
Page 30 Lotus Service Notes Section BV Scribe around the hinge blade on the tailgate to aid refit alignment (if applicable) before supporting the tailgate and removing the hinge blade fixing bolts. Refit in reverse order to removal, adjusting panel shutlines and height as necessary. Check latch engage- ment and release, and adjust striker position if necessary.
Page 31 Lotus Service Notes Section BV BV.4 - FRONT CLAMSHELL The front clamshell comprises a composite moulding forming the front upper bodywork between the base of the windscreen and the front bumper. Incorporated into the panel are apertures for the radiator air outlet grilles, and a recess for the hydraulic fluid and windscreen washer reservoirs.
Page 32 Lotus Service Notes Section BV Front bumper Adjustable support rail Bumper/headlamp support bracket Diffuser spat b359 From each headlamp aperture, release the three fixings clamping the bumper top flange to the clamshell and to the support bracket. From each headlamp aperture, slacken the two nuts securing the front edge of the clamshell and bumper top flange to the support rail.
Page 33 Lotus Service Notes Section BV Boot floor to subframe Clam to roof rear flange Acess from interior Clam to body side b358 Rear clamshell removal/replacement Tailgate: Remove the tailgate (see BV.2), both rear wheels, and wheelarch liners. Ventilation panel: The engine bay outlet ventilation panel around the top edge of the tailgate aperture needs to be removed to provide access the clamshell to roof fixings.
Page 34 Lotus Service Notes Section BV At each side, release the front seat belt upper anchorage from the 'B' post, and pull off the 'B' post top trim. Pull the weatherstrip seal off the body vertical flange at the rear of the door aperture. Pull the rear quarter trim panel away at its top edge to release the two spring fasteners beneath the quarter window.
Page 35 Lotus Service Notes Section BV To remove/refit rear bumper From inside the boot, remove the trim panel from around the latch mechanism, and disconnect the har- nesses to the rear fog and reverse lamps, parking sensors and reverse camera. From within each rear wheelarch, release the single fixing securing the lower edge of the bumper to the subframe bracket, and the two fixings at each side securing the diffuser finisher to the diffuser.
Page 36 Lotus Service Notes Section BV To refit, connect the cables (either way round), hook on the inboard end of the glass carrier, and press the outboard end until the clip is engaged. Note that convex glass is normally fitted to both sides in order to provide the widest field of vision, but certain markets use flat glass on one or both sides.
Page 37: Bv.11
Lotus Service Notes Section BV to the door shell, and one with a double eye for bolting to the chassis hinge post, the oversize holes providing sufficient positional tolerance for door shutline adjustments to be made. Synthetic bushes and a steel tube provide the maintenance free pivot mechanism, with the two hinge halves being mated by a pivot bolt to allow door removal without losing the alignment settings.
Page 38: Bv.12
Lotus Service Notes Section BV BV.11 - DOOR WINDOW, GuIDE RAILS & LIFT MECHANISM WARNING: To ease door closure, and optimise the sealing of the frameless door glass against the weatherstrips, the control mechanism will automatically drop a fully closed window a small distance when the door is opened (preparatory to closing), and raise it again after the door is shut.
Page 39: Bv.13
Lotus Service Notes Section BV Door glass adjustment To provide optimum weather sealing, several adjustments are available to position the glass correctly, with sufficient weatherstrip seal loading. Glass top edge alignment: When fully raised, the glass top edge needs to be aligned to the roof and cant rail seal.
Page 40: Bv.14
Lotus Service Notes Section BV BV.12 - DOOR LATCH MECHANISM The door latch mechanism is fitted inside the rear face of the door, which is reinforced by a steel plate bonded to the composite door shell, and which is also used to secure the rear end of the door beam. The latch engages with a striker hoop which is secured to a bracket integral with the seat belt mounting frame.
Page 41: Bv.15
BV.13 - WINDSCREEN REMOVAL/REPLACEMENT 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.
Page 42 Lotus Service Notes Section BV Slide the interior mirror stem from the windscreen plinth. Remove the sun visor retaining screws to allow the front of the head lining to drop. Pull each 'A' pillar trim panel out from its three captive 'fir tree' fasteners (a fourth fir tree button at its lower end is inaccessible), to protect from adhesive cutting tool damage.
Page 43 Lotus Service Notes Section BV 13. Insert three 6mm spacer blocks A132u0346F into the inside edge of each 'A' pillar bead. 14. Apply suction handles to the glass, and with assistance, carefully fit the glass onto the frame, taking care to position it centrally (compare dimensions at each side between glass and body edges) and with the upper filler strip in uniform contact with the roof edge.
Page 44 Lotus Service Notes Section BV (green cap) A120B6041V. Prime and re-activate the prepared surface of the old adhesive on the tailgate with Betawipe 4000 (A082B6355V). If the tailgate bonding surface is new or without adhesive, prime the tailgate with Betaprime 5404 (red cap) A082B6337V.
Page 45 Lotus Service Notes Section BV After cutting out the glass, remove old adhesive from body flange sufficiently to leave a consistent and flat surface for the new bonding medium. Clean the whole of the bonding surface on the new glass, and the bonding surface on the tailgate aperture, with the wipe cleaner supplied in the Betaseal Kit (or Betaclean 3900 A100B6008V).
Page 46 Lotus Service Notes Section CK FRONT SUSPENSION SECTION CK Sub-Section Page General Description CK.1 Geometry & Adjustments CK.2 Wishbone Pivot Bushes & Swivel Joints CK.3 Anti-Roll Bar CK.4 Suspension Disassembly/Assembly CK.5 Front Wheel Bearings CK.6 Page 1...
Page 47 Lotus Service Notes Section CK General Arrangement Damper 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...
Page 48 Lotus Service Notes Section CK CK.1 - GENERAL DESCRIPTION The independent front suspension comprises, on each side of the car, upper and lower forged aluminium wishbones, a concentric coil spring/telescopic damper unit, and a tubular anti-roll bar. A forged steel hub car- rier, provides a mounting for the hub bearing unit to which the 5-bolt road wheel and brake disc are attached, and also features an integral steering arm and mounting bosses for the brake caliper.
Page 49 Lotus Service Notes Section CK Alignment Wheel alignment refers to the parallelism of the wheels when viewed from above and is crucial to vehicle stability, handling and tyre wear. Difference between rim measurements = overall toe out FRONT Individual toe out...
Page 50 Lotus Service Notes Section CK Camber Adjustment Camber is the angle from vertical of the wheel when viewed from the front, and is said to be negative when the wheel leans inwards at the top (positive when leaning outwards). The primary purpose of camber is to achieve the maximum efficiency of the tyre under cornering loads and body roll, with the specification closely allied to a particular wheel/tyre combination.
Page 51 Lotus Service Notes Section CK Cambolt illustration Castor Adjustment Castor is the angle from vertical of the steering axis of the wheel when viewed from the side. Its primary purpose is to provide a natural straight running tendency of the steered wheels with forward vehicle motion.
Page 52 Lotus Service Notes Section CK To be revised Steering Swivel Joints The steering swivel joint housed in the outboard end of both the top and bottom wishbones, uses a steel ball pin located in a synthetic spherical bearing cup pressed into the wishbone and retained by a swaging op- eration.
Page 53 Lotus Service Notes Section CK CK.5 - SUSPENSION DISASSEMBLY/ASSEMBLY The suspension may be disassembled without the use of any special tools other than spring compressor clamps if the spring and damper are to be separated. With the car on a wheel free lift and with the front wheels removed: Remove the wheelarch liner(s) as appropriate.
Page 54 Lotus Service Notes Section CK 13. If necessary, release the four bolts and remove the damper lower fixing bracket from the lower wishbone, and the remaining bolt securing the anti-roll bar drop link bracket. Anti-Roll Bar 14. At least one of the lower wishbones must be removed before the ARB may be withdrawn.
Page 55 Lotus Service Notes Section CK Anti-roll bar drop links Wheel bolts Speed sensor to hub carrier Brake disc retaining screw CK.6 - FRONT WHEEL BEARINGS 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.
Page 56 Lotus Service Notes Section DJ REAR SUSPENSION SECTION DJ Sub-Section Page General Description DJ.1 Geometry & Adjustments DJ.2 Wishbone Pivot Bushes & Spherical Joints DJ.3 Anti-Roll Bar DJ.4 Suspension Disassembly/Assembly DJ.5 Rear Wheel Bearings DJ.6 Page 1...
Page 57 Lotus Service Notes Section DJ Rear Suspension Layout Spherical joint Spring/damper unit Top wishbone Damper top mounting bracket Calliper mounting Turnbuckle drop link Anti-roll bar Lower wishbone Toe control link ARB chassis Hub unit mounting bush Hub carrier Page 2...
Page 58 Lotus Service Notes Section DJ DJ.1 - GENERAL DESCRIPTION The independent rear suspension comprises, on each side of the car, upper and lower forged aluminium wishbones, a forged steel toe control link, a concentric coil spring/telescopic damper unit, and a tubular steel anti-roll bar, all being attached to the galvanised steel rear subframe.
Page 59 Lotus Service Notes Section DJ Alignment Wheel alignment refers to the parallelism of the wheels when viewed from above and is crucial to vehicle stability, handling and tyre wear. It is measured either by the angle a wheel makes with the vehicle centre line, or the difference in dimension between the wheel rim to wheel rim measurement at the front and rear of the wheel at hub centre height.
Page 60 Lotus Service Notes Section DJ Camber Adjustment Camber is the angle from vertical of the wheel when viewed from the rear, and is said to be negative when the wheel leans inwards at the top (positive when leaning outwards). Camber angle...
Page 61 Lotus Service Notes Section DJ DJ.3 - WIShBONE PIvOT BUShES & SPhERICAL 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 charac- teristic.
Page 62 Lotus Service Notes Section DJ ARB illustration DJ.5 - SUSPENSION DISASSEMBLY/ASSEMBLY The suspension may be disassembled without the use of any special tools other than spring compressor clamps if the sping and damper are to be separated. If the hub carrier is to be removed, necessitating with- drawal of the driveshaft, it is recommended first to release the driveshaft nut before dismantling the brakes, in order that the brakes may be used to react against the release torque.
Page 63 Lotus Service Notes Section DJ 10. Release the two bolts securing the spring top abutment plate to the inside of the subframe tower, and the single bolt (captive nut) securing a leg on the plate to the front face of the tower. Withdraw the complete spring/damper/abutment plate assembly.
Page 64 Lotus Service Notes Section DJ Torque Settings: Upper and lower wishbone pivot bolts Upper wishbone to hub carrier Lower wishbone to hub carrier Toe-link outer ball joint to hub carrier Toe-link inner ball joint to subframe Toe-link turnbuckle locknuts Damper to lower wishbone...
Page 65 Lotus Service Notes Section DJ To Replace hub Bearing Assembly With the car on a wheel free lift and with the rear wheel and engine undertray removed: Firmly apply the parking and footbrakes, and remove the driveshaft nut (both Rh thread).
Page 66 Lotus Service Notes Section EJ ENGINE SECTION EJ Sub-Section Page Introduction EJ.1 Air Cleaner Element Inspection/Replacement EJ.2 Engine Oil & Filter Change EJ.3 Auxiliary Drive Belt EJ.4 Engine Removal/Replacement EJ.5 Engine Special Tools EJ.6 Engine Repair (CD T000T1506) EJ.7 Page 1...
Page 67 Dual VVT-i (Variable Valve Timing-intelligent) system, DIS (Direct Ignition System), ACI c Control Induction System), and ETCS-i (Electronic Throttle Control System-intelligent). Thes unctions achieve improved engine performance, fuel economy, and reduced exhaust emissions. Lotus Service Notes Section EJ EJ.1 - INTRODUCTION...
Page 68 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 Toyota, and installed in the engine bay with transmission on the left hand side.
Page 69 Lotus Service Notes Section EJ again for correct mating. Continue re-assembly in reverse order to removal. EJ.3 - ENGINE OIL & FILTER CHANGE The engine oil hex. head drain plug is located in the base of the pressed steel sump.
Page 70 Lotus Service Notes Section EJ ring does not become displaced. Using special tool T000T1511, torque tighten the cap to 25 Nm. Check that there is no clearance between cap and housing. Lubricate the small ‘O’ ring supplied with the new filter with engine oil, and fit into the groove in the filter housing.
Page 71 Lotus Service Notes Section EJ CV joints will be damaged and require replacement. Apply pressure only to the body of the inboard joint. Withdraw the complete LH hub carrier and driveshaft assembly, taking care not to damage the transmission output shaft oil seal.
Page 72 Then select from the menu for an overview of the engine features. Insert disc 'HTML' Global Service Information Centre will open up. Select: - ENGINE From menu section relating to the 2GR-FE engine, select topic required. Be aware of installation differ- ences for the Lotus application. Page 7...
Page 73 Lotus Service Notes Section EMR ENGINE MANAGEMENT SECTION EMR Sub-Section Page Diagnostic Trouble Code List EMR.1 CAN Bus Diagnostics; Lotus TechCentre EMR.2 Page 1 2009/02...
Page 74 Lotus Service Notes Section EMR NOTES Cylinder Numbering - viewed from above: LH cylinder bank (2) Rear of engine Front of engine (flywheel end) (auxiliary drive belt end) RH cylinder bank (1) Page 2 2009/02...
Page 75 Lotus Service Notes Section EMR EMR.1 - DIAGNOSTIC TROUBLE CODE (DTC) LIST Fault description Page P0011 A Camshaft Position - Timing Over-Advanced or System Performance - Bank 1 P0012 A Camshaft Position - Timing Over-Retarded - Bank 1 P0014 B Camshaft Position - Timing Over-Advanced or System Performance - Bank 1...
Page 76 Lotus Service Notes Section EMR .....Continued Fault description Page P0160 O2 Sensor Circuit No Activity Detected (Post Catalyst) – Bank2 P0161 O2 Sensor Heater Circuit (post Catalyst) – Bank2 P0171 System Too Lean – Bank1 P0172 System Too Rich – Bank1 P0174 System Too Lean –...
Page 77 Lotus Service Notes Section EMR .....Continued Fault description Page P0453 Evaporative Emission System Pressure Sensor/Switch High P0455 Evaporative Emission System Leak Detected (large leak) P0456 Evaporative Emission System Leak Detected (very small leak) P0461 Fuel Level Sensor “A” Circuit Range/Performance P0462 Fuel Level Sensor “A”...
Page 78 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, the connections for which may be found in circuit diagrams in Section MR. Diagnostic Trouble Codes should be read using the Lotus TechCentre.
Page 79 Lotus Service Notes Section EMR MR.2 - COMPONENT FUNCTION Component Function Mass Air Flow Meter Engine load detection Intake Air Temperature Sensor Air temperature detection Engine Coolant Temperature Sensor Engine coolant temperature detection Throttle Position Sensor Determines engine throttle position...
Page 80 Lotus Service Notes Section EMR Component Function Cooling Fan 1 Relay Actuates cooling fan 1 Cooling Fan 2 Relay Actuates cooling fan 2 Air Conditioning Control Relay Actuates air conditioning compressor Air Conditioning Control Valve Regulates air conditioning compressor load...
Page 81 Lotus Service Notes Section EMR EMR.3 - COMPONENT LOCATION em239 Page 9 2009/02...
Page 82 Lotus Service Notes Section EMR em240 Page 10 2009/02...
Page 83 Lotus Service Notes Section EMR EMR.4 - DIAGNOSTIC GUIDE Camshaft Timing Control (VVT) P0011 Camshaft Position – Inlet Timing Over-Advanced or System Performance (Bank 1) P0012 Camshaft Position – Inlet Timing Over-Retarded (Bank 1) P0014 Camshaft Position – Exhaust Timing Over-Advanced or System Performance (Bank 1) P0015 Camshaft Position –...
Page 84 Lotus Service Notes Section EMR Crankshaft Position–Camshaft Position Correlation Error P0016 Crankshaft position – camshaft position correlation – bank 1 sensor A (Inlet) P0017 Crankshaft position – camshaft position correlation – bank 1 sensor B (Exhaust) P0018 Crankshaft position – camshaft position correlation – bank 2 sensor A (Inlet) P0019 Crankshaft position –...
Page 85 Lotus Service Notes Section EMR Camshaft Timing Control (VVT) P0076 Intake Valve Control Solenoid Circuit Low (Bank1) P0077 Intake Valve Control Solenoid Circuit High (Bank1) P0079 Exhaust Valve Control Solenoid Circuit Low (Bank1) P0080 Exhaust Valve Control Solenoid Circuit High (Bank1)
Page 86 Lotus Service Notes Section EMR -Intake Air Flow P0101 Mass or Volume Air Flow Circuit Range/Performance P0102 Mass or Volume Air Flow Circuit Low Input P0103 Mass or Volume Air Flow Circuit High Input Description The Mass Air Flow (MAF) sensor is incorporated into the airbox, and measures both intake air flow rate and Intake Air Temperature (IAT).
Page 87 Lotus Service Notes Section EMR Disable Criteria: • None Malfunction Criteria: • Voltage at ECU < 0.52V for time > 1.5 secs Potential failure modes: • MAF sensor circuit open • MAF sensor circuit short to ground 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...
Page 88 Lotus Service Notes Section EMR Barometric Pressure P0106 Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance P0107 Manifold Absolute Pressure/Barometric Pressure Circuit Low Input P0108 Manifold Absolute Pressure/Barometric Pressure Circuit High Input Description The barometric pressure sensor 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.
Page 89 Lotus Service Notes Section EMR Intake Air Temperature P0111 Intake Air Temperature Sensor 1 Circuit Range/Performance P0112 Intake Air Temperature Sensor 1 Circuit Low P0113 Intake Air Temperature Sensor 1 Circuit High Description The combined sensor which measures both Mass Air Flow (MAF) and Intake Air Temperature (IAT) is incorpo- rated into the air box.
Page 90 Lotus Service Notes Section EMR P0112 Monitor: • Continuous Disable Criteria: • None Enable Criteria: • Engine running Malfunction Criteria: • Inlet air temperature > 119°C (246°F) for time > 1.5 secs Potential failure modes: • Signal short circuit • 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...
Page 91 Lotus Service Notes Section EMR Engine Coolant Temperature P0116 Engine Coolant Temperature Circuit Range/Performance P0117 Engine Coolant Temperature Circuit Low P0118 Engine Coolant Temperature Circuit High Description The engine coolant temperature sensor is a thermistor device which changes resistance with temperature. As coolant temperature decreases the thermistor resistance value increases, and conversely as coolant tempera- ture increases so the thermistor resistance value decreases.
Page 92 Lotus Service Notes Section EMR Enable Criteria: • Engine running Malfunction Criteria: • Coolant temperature > 119°C (246°F) for time > 1.5 secs Potential failure modes: • Signal short circuit • Sensor failure • Thermostat failure • Cooling 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...
Page 93 Lotus Service Notes Section EMR Throttle Position P0122 Throttle Position Sensor 'A' Circuit Low P0123 Throttle Position Sensor 'A' Circuit High P0222 Throttle Position Sensor ‘B’ Circuit Low P0223 Throttle Position Sensor ‘B’ Circuit High Description The throttle position sensor (TPS) is mounted on the throttle body, and detects the opening angle of the throt- tle valve.
Page 94 Lotus Service Notes Section EMR Disable Criteria: • None Malfunction Criteria: • Signal voltage > 4.765V Potential failure modes: • Signal open circuit • Reference voltage open circuit • Reference voltage short to ground • Sensor failure Diagnostic Mask: • The MIL will be illuminated if fault is present. P0222 Monitor: • Continuous. Enable Criteria: • None Disable Criteria: • None Malfunction Criteria: • Signal voltage < 2.146V...
Page 95 Lotus Service Notes Section EMR Potential failure modes: • Signal open 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 may be applied.
Page 96 Lotus Service Notes Section EMR Coolant Thermostat (USA only) P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) Page 24 2009/02...
Page 97 Lotus Service Notes Section EMR O2 Sensor (Pre Catalyst) P0131 O2 Sensor 1 Circuit Low Voltage (Bank 1) P0132 O2 Sensor 1 Circuit High Voltage (Bank 1) P0133 O2 Sensor 1 Circuit Slow Response (Bank 1) P0134 O2 Sensor 1 Circuit No Activity Detected (Bank 1)
Page 98 Lotus Service Notes Section EMR Potential failure modes: • Low fuel pressure (Lean mixture) • Malfunctioning sensor • External water on sensor • Sensor wire shorted to ground Diagnostic Mask: • The MIL will be illuminated if these faults are present for 2 consecutive trips. P0132 (Bank1) or P0152 (Bank2) Monitor: • Continuous. Disable Criteria: • None Enable Criteria: • Engine running Malfunction Criteria: • Sensor voltage > 1200V for more than 1.5 seconds consecutively for a specified number of times.
Page 99 Lotus Service Notes Section EMR Malfunction Criteria: • Set when the sensor fails to switch from a Lean to a Rich condition or switch from a Rich to a Lean condition in a sufficiently timely manner. A selection of switches is used to determine the average times. “highlighted section removed” Potential failure modes: • Sensor connector and wiring should be checked for corrosion and loose connections • Sensor contaminated, possibly from fuel, improper use of RTV, engine oil or coolant Diagnostic Mask: • The MIL will be illuminated if these faults are present for 2 consecutive trips. P0134 (Bank1) or P0154 (Bank2) Monitor: • Until either passed or failed.
Page 100 Lotus Service Notes Section EMR O2 Sensor (Post Catalyst) P0137 O2 Sensor Circuit Low Voltage (Bank 1) P0138 O2 Sensor Circuit High Voltage (Bank 1) P0139 O2 Sensor Circuit Slow Response (Bank 1) P0140 O2 Sensor Circuit No Activity Detected (Bank 1)
Page 101 Lotus Service Notes Section EMR Potential failure modes: • Check and rectify any pre catalyst sensor fault code, as they may be causing the fault code to be set • Sensor wire shorted to ground • Catalyst Diagnostic Mask: • The MIL will be illuminated if these faults are present for 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.
Page 102 Lotus Service Notes Section EMR P0140, P0160 Monitor: • Continuous Enable Criteria: • Engine run time > 30 seconds • Engine is not at idle • Engine is in closed loop fuel control • Oxygen sensors ready Disable Criteria: • None Malfunction Criteria: • Set when the sensor fails to switch above 673mV and below 400mV within 60 seconds. Potential failure modes: • Check and rectify any front sensor fault code, as they may be causing the fault code to be set • Sensor 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.
Page 103 Lotus Service Notes Section EMR Fuel Control System Too Lean Or Rich P0171 System Too Lean (Bank 1) P0172 System Too Rich (Bank 1) P0174 System Too Lean (Bank 2) P0175 System Too Rich (Bank 2) Description The oxygen sensor sends a signal to the ECU corresponding to the exhaust gas oxygen content enabling the ECU to maintain a 14.7:1 air/fuel ratio under normal driving conditions.
Page 104 Lotus Service Notes Section EMR Malfunction Criteria P0172, P0175: • These codes will be set when the relevant bank learned fuel correction has been decreased to its minimum limit of -25% and the system still cannot maintain an air/fuel ratio of 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...
Page 105 Lotus Service Notes Section EMR Fuel Injection System P0261 Injector Circuit low voltage – Cylinder 1 P0262 Injector Circuit high voltage – Cylinder 1 P0264 Injector Circuit low voltage – Cylinder 2 P0265 Injector Circuit high voltage – Cylinder 2 P0267 Injector Circuit low voltage –...
Page 106 Lotus Service Notes Section EMR Misfire P0300 Random/Multiple Cylinder Misfire Detected P0301 Cylinder 1 Misfire Detected P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected Description A misfiring cylinder can be detected by analysing crank speed variation.
Page 107 Lotus Service Notes Section EMR Potential failure modes: • Injectors or related codes • VVT system (clearance or timing) 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. Page 35 2009/02...
Page 108 Lotus Service Notes Section EMR Knock Control System P0327 Knock Sensor Circuit Low (Bank 1) P0328 Knock Sensor Circuit High (Bank 1) P0332 Knock Sensor Circuit Low (Bank 2) P0333 Knock Sensor Circuit High (Bank 2) Description The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The piezoelectric element sends continuously sends a signal to the ECU, when the cylinder block vibrates due to engine knocking this signal increases.
Page 109 Lotus Service Notes Section EMR Engine Speed / Position Sensors P0335 Crankshaft Position Sensor “A” Circuit Range/Performance Description Engine speed is calculated by measuring the time between the ‘teeth’ of the crankshaft sensor trigger disc. The disc has 34 ‘teeth’ and 2 missing ‘teeth’, spaced at 10 degree intervals around the disc. The 2 missing ‘teeth’...
Page 110 Lotus Service Notes Section EMR Engine Speed / Position Sensors P0341 Camshaft Position Sensor “A” Circuit (Bank 1) P0346 Camshaft Position Sensor “A” Circuit (Bank 2) P0366 Camshaft Position Sensor “B” Circuit (Bank 2) P0391 Camshaft Position Sensor “B” Circuit (Bank 2)
Page 111 Lotus Service Notes Section EMR Ignition System P0351 Ignition Coil “A” Primary/Secondary Circuit P0352 Ignition Coil “B” Primary/Secondary Circuit P0353 Ignition Coil “C” Primary/Secondary Circuit P0354 Ignition Coil “D” Primary/Secondary Circuit P0355 Ignition Coil “E” Primary/Secondary Circuit P0356 Ignition Coil “F” Primary/Secondary Circuit Description A Direct Ignition System (DIS) is used on the engine.
Page 112 Lotus Service Notes Section EMR Catalyst System Efficiency P0420 Catalyst System Efficiency Below Threshold (Bank 1) P0430 Catalyst System Efficiency Below Threshold (Bank 2) Description The ECU compares the waveform of the oxygen sensors located before and after the catalyst to determine whether or not the catalyst has deteriorated.
Page 113 Lotus Service Notes Section EMR Disable Criteria: • P0101, P0102, P0103 – MAF faults • P0107, P0108 – MAP / Baro Faults • P0116, P0117, P0118 – Coolant temperature faults • P0131, P0132, P0133, P0134, P0135, P0137, P0138, P0139, P0140, P0141 – Oxygen sensor faults B1 • P0151, P0152, P0153, P0154, P0155, P0157, 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...
Page 114 Lotus Service Notes Section EMR Evaporative Emission Control – 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)
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Page 117 Lotus Service Notes Section EMR Evaporative Emission Control – Purge, Open / Closed Circuit P0444 Evaporative Emission System Purge Control Valve Circuit Open P0445 Evaporative Emission System Purge Control Valve Circuit Closed P0446 Evaporative Emission System Vent Control Circuit P0447...
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Page 119 Lotus Service Notes Section EMR Fuel Level Sensor P0461 Fuel Level Sensor “A” Circuit Range/Performance P0462 Fuel Level Sensor “A” Circuit Low P0463 Fuel Level Sensor “A” Circuit High Description When the engine is running the ECU continuously monitors the fuel level sensor feedback signals. The feedback signal should be low when turned ON and high when turned OFF.
Page 120 Lotus Service Notes Section EMR Enable Criteria 2: • 12 litres fuel usage in upper region • 10 litres fuel usage in lower region • 5 litres fuel usage in mid region Disable Criteria: • Vehicle stopped for 30 secs Malfunction Criteria: • Checks for three conditions, stuck when full, stuck when empty or stuck midway. The ECU determines if the sensor is stuck by calculating the amount of fuel used during the test period. If the fuel level does not move by more than 1 litre a fault is flagged.
Page 121 Lotus Service Notes Section EMR Engine Cooling Fan Control P0480 Fan 1 Control Circuit P0481 Fan 2 Control Circuit Component connections Sensor Connector Description ECU Pin ECU Connector Fan Relay 3 48 Way (Right) Fan Relay 2 48 Way (Right) Monitor: • Continuous...
Page 122 Lotus Service Notes Section EMR Vehicle Speed Sensor P0500 Vehicle Speed Sensor “A” Description This input to the ECU is from the ABS module via CAN. Monitor: • Continuous Enable Criteria: • 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...
Page 123 Lotus Service Notes Section EMR Idle Speed Control P0506 Idle Air Control System RPM Lower Than Expected P0507 Idle Air Control System RPM Higher Than Expected Description The ECM controls the engine idle speed using a combination of spark advance and throttle blade adjustment.
Page 124 Lotus Service Notes Section EMR A/C Evaporator temperature sensor P0537 A/C Evaporator temperature sensor circuit low P0538 A/C Evaporator temperature sensor circuit high Description The A/C system incorporates an evaporator temperature sensor for system control. This is a thermistor device that changes resistance with temperature.
Page 125 Lotus Service Notes Section EMR Battery Voltage P0562 System Voltage Low P0563 System Voltage High Description With a battery and alternator functioning as normal the system voltage for a running engine should be around 14V. The ECM monitors this and will diagnose if the voltage is too high or too low.
Page 126 Lotus Service Notes Section EMR Cruise Control P0564 Cruise control multi-function input signal P0578 Cruise control multi-function input “A” circuit stuck P0571 Brake switch “A” circuit Description Cruise control requests are made using a multi-function switch input. Each cruise control function switch selects a different resistive network to a single ECM input.
Page 127 Lotus Service Notes Section EMR Malfunction Criteria 1: • Brake switch on for greater than 25.5 seconds Malfunction Criteria 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. Page 55 2009/02...
Page 128 Lotus Service Notes Section EMR ECU Integrity P0601 Checksum P0606 Watchdog Description These codes are used by the ECU to check the integrity of the software and calibration data. P0601 checks that on power up the checksum for calibration data is the same as checksum saved on the previous power down.
Page 129 P0610 Variant code not programmed Description The ECM programming 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...
Page 130 Lotus Service Notes Section EMR Crank Relay P0616 Starter relay voltage low P0617 Starter relay voltage high Description When the ignition key is in the crank position battery voltage is applied to the start request input of the ECM. The ECM will then energise the crank relay, via the immobiliser, to allow the starter motor to be engaged.
Page 131 Lotus Service Notes Section EMR Fuel Pump Relay P0628 Fuel Pump “A” Control Circuit Low Voltage P0629 Fuel Pump “A” Control Circuit High Voltage Description The fuel system is of the non-return type. The fuel pump is incorporated into the fuel tank module, which also contains the level sensor, fuel pressure regulator and vapour pressure sensor.
Page 132 P0630 Vin not programmed or incompatible Description The ECM programming 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...
Page 133 Lotus Service Notes Section EMR Throttle Actuator Control Range/Performance P0638 Throttle actuator control range/performance Description The single throttle butterfly valve mounted at the inlet to the intake plenum is operated by a stepper motor under the command of the engine ECU. The valve moves through a range of nearly 90° and should display 100% at full throttle and around 2% at idle.
Page 134 Lotus Service Notes Section EMR Air Conditioning System P0646 A/C Clutch Relay Control Circuit Low P0647 A/C Clutch Relay Control Circuit High Description The ECM controls the A/C clutch relay in response to the A/C driver request and ECM control logic.
Page 135 Lotus Service Notes Section EMR Variable intake manifold circuit P0661 Variable intake manifold circuit voltage low P0662 Variable intake manifold circuit voltage high Description This circuit opens and closes the variable intake manifold (VIM) in response to changes in the engine speed and load in order to increase the intake efficiency.
Page 136 Lotus Service Notes Section EMR Clutch position sensor circuit P0806 Clutch position sensor circuit range/performance P0807 Clutch position sensor circuit low P0808 Clutch position sensor circuit high Description The clutch position sensor is used to identify the position of the clutch (engaged, disengaged or slipping). This information is used to control features such as fuel cut during gear changes, cruise control deactivation and ensuring any torque increase requests from the ESP system only occur with the clutch engaged.
Page 137 Lotus Service Notes Section EMR Potential failure modes: • P0807 – Clutch sensor wiring open circuit 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. Page 65 2009/02...
Page 138 Lotus Service Notes Section EMR Air intake control valve circuit P1113 Air intake control valve circuit Description: The air cleaner is equipped with 2 inlets, one of which is opened or closed by the Air Intake Control Valve (AICV). This system reduces intake noise and increases engine power.
Page 139 Lotus Service Notes Section EMR Misfire P1301 Misfire level causing emissions increase P1302 Misfire level causing catalyst system damage Description When the engine misfire reaches a high enough percentage the engine emission output levels can exceed the allowed limits, this will produce the fault code P1301.
Page 140 Lotus Service Notes Section EMR Coolant Recirculation Pump P2602 Coolant Pump Control Circuit Low P2603 Coolant Pump Control Circuit High Description During a hot shutdown of the engine, the recirculation pump can continue to pump coolant around the engine. The recirculation pump will run after the engine has been turned off if the enable criteria are matched.
Page 141 Lotus Service Notes Section EMR Throttle Actuator Control Motor Circuit/Open P2100 Throttle actuator control motor circuit open Description The throttle actuator stepper motor operates on 12 volts. Monitor: • Continuous Enable Criteria: • None Disable Criteria: • None Potential failure modes: • Throttle actuator control motor open circuit...
Page 142 Lotus Service Notes Section EMR Throttle Actuator Control System – Forced Idle P2104 Throttle actuator control system – forced idle Description If a problem is detected which could result in faster engine speed than commanded by the pedal, the actuator is switched out, allowing the throttle valve to default to a 6% mechanically sprung setting.
Page 143 Lotus Service Notes Section EMR Throttle Actuator Control System – Forced Limited Power P2106 Throttle actuator control system – forced limited power Description If a problem is detected which could result in engine speed control difficulties, the ECU will limit throttle opening to a maximum of 15%.
Page 144 Lotus Service Notes Section EMR Throttle Actuator Control Module Performance P2108 Throttle actuator control module performance Monitor: • Continuous Enable Criteria: • Engine running Disable Criteria: • None Potential failure modes: • ECU internal failure • Short circuit to throttle actuator Pedal Position Sensor 'D' Circuit Low P2122 Pedal position sensor ‘D’...
Page 145 Lotus Service Notes Section EMR Pedal Position Sensor 'D' Circuit High P2123 Pedal position sensor ‘D’ circuit high Enable Criteria: • None Disable Criteria: • None Potential failure modes: • Signal open circuit (> 4.487 V) • Reference voltage open circuit • Reference voltage short to ground • Sensor failure Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple codes, a mechanically sprung 7% opening may be applied.
Page 146 Lotus Service Notes Section EMR Pedal Position Sensor 'E' Circuit High P2128 Pedal position sensor ‘E’ circuit high Enable Criteria: • None Disable Criteria: • None Potential failure modes: • Signal open circuit (> 4.487 V) • Reference voltage open circuit • Reference voltage short to ground • Sensor failure Notes: A maximum throttle opening of 15% may be imposed due to this single code. In the case of multiple codes, a mechanically sprung 7% opening may be applied.
Page 147 Lotus Service Notes Section EMR Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation P2138 Pedal position sensor/switch ‘D/E’ voltage correlation Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU. Two processors within the ECU compare the two output signals, which should match within a defined tolerance.
Page 148 Lotus Service Notes Section EMR A/C Refrigerant Distribution Valve P2612 A/C Refrigerant Distribution Valve Control Circuit Low P2613 A/C Refrigerant Distribution Valve Control Circuit High Description: The A/C refrigerant flow is regulated by the ECM using the distribution valve to control the evaporator to the required temperature and prevent freezing.
Page 149 Lotus Service Notes Section EMR A/C Compressor Lock Sensor Circuit B1422 A/C Compressor Lock Sensor Circuit Description: The ECM monitors the A/C compressor speed. If this speed is lower than the engine speed the ECM will turn off the A/C compressor clutch. This is to prevent belt damage due to slippage.
Page 150 Lotus Service Notes Section EMR Lost Communications with TCM U0101 Lost Communications with TCM Description: The ECM communicates with the Transmission Control Module (TCM) via the CAN bus. If these CAN bus communications have been interrupted the ECM will register a diagnostic code.
Page 151 Lotus Service Notes Section EMR Software Incompatible with VDCM U0316 Software Incompatible with VDCM Description: The ECM checks that the Vehicle Dynamic Control Module (VDCM) matches the vehicle variant code. If not the above code will be set and the ECM will not respond to torque requests from the VDCM.
Page 152 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.
Page 153 Lotus Service Notes Section FL TRANSMISSION SECTION FL Sub-Section Page Introduction FL.1 Gearchange Mechanism FL.2 Lubrication FL.3 Driveshafts FL.4 Transmission Removal/Replacement FL.5 Transmission Overhaul FL.6 Page 1...
Page 154 EA60 AND EA61 MANUAL TRANSAXLE 1. General Lotus Service Notes Section FL EA60/EA61 manual transaxles are newly developed 6-speed manual transaxles. These transaxles realize compact construction and excellent shift feeling due to the following items. GENERAL LAYOUT Feature Item · Twin (No.1 and No.2) output shafts are used.
Page 155 Note that the Ea60 transmission is not used by Toyota in combination with the 2GR-FE V6 engine. For the Evora application, a fully machined, cast alloy adaptor plate is interposed between the engine and transmis- sion, the clutch housing of which is machined to accept the mounting of the starter motor via a further adaptor block.
Page 156 Lotus Service Notes Section FL Crossgate cable Shift cable to to transmission transmission Lift collar Abutment bracket on transmission Shift cable Crossgate cable Gear lever/parking brake mounting bracket pl4705eg Gearchange Cable Adjustment In order to ensure smooth selection of 1st/2nd gears, it is important to set the crossgate cable adjustment in relation to the fixed position reverse inhibitor block.
Page 157 Lotus Service Notes Section FL Hairpin spring Bellcrank lever Grease these areas Pivot stud Fixing to floor channel Gearchange Cable Replacement For access to the gear cables, the gear lever shroud and parking brake lever trim panel must be removed, and the gear lever/parking brake support channel released from the chassis tub floor: Remove centre console: See sub-section VE.5.
Page 158 Lotus Service Notes Section FL FL.3 - LUBRICaTION The engine and transmission should be inspected for evidence of oil leaks at every service, and the trans- mission oil renewed at intervals specified in the Maintenance Schedule. The transmission should be drained after a run when the oil is warm, flows more readily, and the impurities are still held in suspension.
Page 159 Lotus Service Notes Section FL Clicking noises, torque reversal 'clonks', or shudder and vibration when accelerating are all possible symptoms of worn C.V. joints. It should not be possible to discern any free play in a joint by manual manipula- tion, but care must be taken not to confuse this with transmission backlash, which may be considerable.
Page 160 Lotus Service Notes Section FL 10. Lubricant: With the car on the level, top up the transmission oil to the filler/level plug hole (see above). 11. Wheel and Undertray: Refit the road wheel and undertray. Driveshaft C.V. Joint and/or Gaiter Replacement The outboard C.V.
Page 161 Lotus Service Notes Section FL Remove the circlip from the outboard face of the bearing housing, and press or pull the housing from the bearing. Prise or pull the bearing dust shield off the shaft. Remove the circlip retaining the bearing and press or pull the bearing from the shaft.
Page 162 To separate the engine/transmission assembly In order to mate the 2GR-FE engine to the Ea60 manual transmission for use in the Evora, a Lotus specific fully machined cast alloy adaptor plate is used between the two units. Space to mount the starter motor in the...
Page 163 Lotus Service Notes Section GJ WHEELS & TYRES SECTION GJ Sub-Section Page General Description GJ.1 Tyre Pressure Monitoring System (TPMS) GJ.2 Wheels GJ.3 Wheel Bolts GJ.4 Tyres GJ.5 Winter Tyres & Snow Chains GJ.6 Punctured Tyre Emergency Inflator GJ.7 Page 1...
Page 164 In order to maintain the correct handling feel and minimum steering wheel shake, it is very important that the radial and lateral run out of the tyres are to the high standard required by Lotus Cars.
Page 165 Standard wheels on the Lotus Evora are Lotus styled, cast alloy, 10-spoke arranged in pairs, silver or grey painted, in sizes of 8.0J x 18 front, and 9.5J x19 rear. Optional forged alloy wheels are Lotus styled with 10 equally spaced radial spokes, but are otherwise similar. Each wheel is located by a central spigot and secured by five bolts, four of which have a spline socket head, and one with a security coded head.
Page 166 GJ.5 - TYRES The Pirelli P-Zero tyres fitted to the Evora are suitable for all normal weather conditions. The tyre char acteristics include good feedback (‘feel’) from the road surface to the steering wheel, a high level of steering linearity and response, and little performance degradation with the raised temperatures which may be reached in high speed use.
Page 167 If the car is to be used in very cold climates, or driven on snow covered roads, it is recommended to fit a complete vehicle set of winter tyres developed specifically for such conditions. For the Evora, Lotus recom- mends the use of Yokohama W.drive V-902 winter tyres in sizes specified below.
Page 168 GJ.7 - PUNCTURED TYRE EMERGENCY INFLATOR (If fitted) In order fully to exploit the benefits of light weight, and to maximise stowage space, the Evora has no provision for spare wheel carriage or lifting jack. A temporary puncture sealing facility is provided in the form of an...
Page 169 Lotus Service Notes Section HI STEERING SECTION HI Sub-Section Page General Description HI.1 Power Steering Rack Operation HI.2 PAS Fluid Check & Refill Procedure HI.3 Steering Wheel HI.4 Steering Column Assembly HI.5 Intermediate Column HI.4 Track Rod Ends & Rack Gaiters HI.5...
Page 170 Lotus Service Notes Section HI Column and Rack Assembly Upper column 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...
Page 171 Section HI HI.1 - GENERAL DESCRIPTION The power assisted steering system of the Evora comprises a column assembly, adjustable for height and reach, connected via two universal joints and an intermediate shaft, to a rack and pinion steering gear mounted on the chassis front subframe ahead of the front axle line.
Page 172 Lotus Service Notes Section HI Connection pin Splines to intermediate shaft Input shaft/valve rotor Torsion bar Hydraulic seal Roller bearing Outlet to reservoir Valve body To/from rack cylinder 1 Inlet from pump Sealing rings To/from rack cylinder 2 Valve sleeve...
Page 173 Lotus Service Notes Section HI Power Steering Schematic (RHD shown) PAS reservoir 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...
Page 174 Lotus Service Notes Section HI The schematic diagram below shows the principle of valve control, although in practice, six pockets are machined in the rotor and sleeve, and the valve system is repeated three times. The valve sleeve is provided with four sealing rings in order to divide the inlet and outlet feeds and connect with ports in the valve body, whilst allowing 360°rotation of the valve assembly.
Page 175 Turn off the ignition. Before disconnecting the battery, use the Lotus TechCentre to read any stored trouble codes. iii) Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the battery negative terminal can be made.
Page 176 Lotus Service Notes Section HI Unclip the top part of the column shroud, then remove the lower part after releasing the three retaining screws. Locate and unplug the airbag harness from the rotary connector. Note that the connector socket is fitted with 'shorting bars' which automatically interconnect the high and low terminals of the airbag to prevent unschedules deployment caused by a voltage differential.
Page 177 Lotus Service Notes Section HI HI.5 - STEERING COLUMN ASSEMBLY The steering column assembly includes a two-piece upper inner column, consisting of two tubes ('A' up- per; 'B' lower) with a sliding splined joint to accommodate reach adjustment, articulated via a universal joint to a similarly constructed two-piece ('C' upper;...
Page 178 Lotus Service Notes Section HI Disconnect the steering angle sensor, and release its mounting bracket from the scuttle. Release the clamp securing the sensor to the column. Remove the front undertray and remove the pinch bolt securing the lower universal joint to the rack pinion shaft and match mark the joint.
Page 179 Lotus Service Notes Section HI Illustration of track rod adjustment Note that in order to preserve the required bump steer characteristic and steering symmetry, the effective length of each track rod must remain equal; compare dimensions and equalise if necessary before subsequently adjusting each track rod by a similar amount: Slacken the rack gaiter outboard clips.
Page 180 Lotus Service Notes Section HI To Remove/Replace Steering Rack Assembly The steering rack may be removed from the front subframe after first removing the front anti-roll bar with its mounting brackets. Remove both front wheels, and the front undertray. Release the anti-roll bar from the drop link at each side.
Page 181 Lotus Service Notes Section HI Check auxiliary drive belt condition and fluid level. With engine idling, turn the steering from lock to lock several times to raise fluid temperature and check for foaming or emulsification; if necessary, bleed the system (see Sub-Section HI.3).
Page 182 Lotus Service Notes Section HI With the pump port axis vertical, check that the valve (lubricated with PAS fluid) falls smoothly into the port. If any stickiness is apparent, replace the pump. Check the valve for leakage: Close off one of the ports in the side of the valve, and apply 450 kPa (65 psi) of compressed air to the opposite port.
Page 183 JL.7 Brake Master Cylinder JL.8 Vacuum Servo Unit JL.9 Pedal Box JL.10 ABS Theory of Operation JL.11 ABS Electro-Hydraulic Unit JL.12 Wheel Speed Sensors JL.13 Data Link Connector (DLC) JL.14 Special Tools JL.15 Lotus TechCentre Checking Procedures JL.16 Page 1...
Page 184 Lotus Service Notes Section JL Page 2...
Page 185 Section JL JL.1 - GENERAL DESCRIPTION The braking system of the Lotus Evora comprises a four piston calliper and brake disc at each wheel op- erated by a tandem master cylinder with dual diaphragm vacuum servo power assistance. The dual hydraulic circuit is divided front/rear and modulated by a Kelsey-Hayes microprocessor based anti-lock system.
Page 186 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).
Page 187 Connect the Lotus Techcentre to the diagnostic link, select ABS and follow the brake bleeding instructions. Whilst this automatic process is taking place (with all 4 calliper nipples open), gently cycle the brake pedal up and down whilst keeping the reservoir topped up, to move any air bubbles displaced from the ABS unit down the hydraulic lines.
Page 188 Lotus Service Notes Section JL If the thickness of any pad is below the specified minimum, the axle set of pads should be renewed. To remove the brake pads; Use a pin punch to tap one of the pad retaining pins towards the inboard side.
Page 189 Lotus Service Notes Section JL Ensure the customer is made aware that maximum braking efficiency will be achieved if, for the first few hundred miles, needless heavy braking is avoided, and the brake pads are allowed to ‘bed in’ fully before being used to their full potential.
Page 190 Lotus Service Notes Section JL The cable adjuster may then be tightened to remove slack until the 'click' specification is achieved. Check that there is no brake drag with the lever fully off. Parking Brake Shoes Unless the parking brake shoes are mal-adjusted, the shoe material should suffer little wear. To remove the shoes, remove the road wheel, fully slacken the brake shoe adjuster, and remove the brake disc (see below).
Page 191 Lotus Service Notes Section JL Remove the two bolts securing the brake calliper to the hub carrier, and withdraw the calliper from the disc. Secure clear without straining the flexible hose. Remove the single countersunk screw, and withdraw the disc from the hub.
Page 192 Lotus Service Notes Section JL Release the two nuts securing the master cylinder to the brake servo and remove the cylinder. 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;...
Page 193 Lotus Service Notes Section JL Tandem Servo Section (brakes off) Vacuum supply Atmospheric Driving piston chambers Pliant reaction disc Atmospheric Communication Atmospheric valve face Input Air filter Front/rear communication Input piston Main spring Vacuum communication j194 Vacuum chambers Atmospheric communication...
Page 194 Lotus Service Notes Section JL Setting brake pedal: It is essential that the servo piston (and master cylinder piston) is allowed to return fully when the brakes are released, and is not pre-loaded by mal-adjustment of the input pushrod. See (4) below.
Page 195 The Bosch antilock brake system is an ‘add on’ type used to supplement the dual circuit, tandem master cylinder, vacuum servo assisted brakes fitted to the Evora. A single electro-hydraulic unit comprising a hydraulic modulator, hydraulic pump, microprocessor and solenoid valve bank, is flexibly mounted on the forward side of the driver's toebox, and plumbed into the front and rear brake circuit lines from the tandem master cylinder.
Page 196 Lotus Service Notes Section JL Anti-Lock Braking Maximum braking force is provided from a tyre when there is around 15% slippage, dependent on road surface conditions and tyre characteristics. The function of the ABS is to limit tyre slippage when braking to around this figure in order to provide optimum grip, and also, by preventing wheel lock, to ensure that steering control of the vehicle is retained.
Page 197 Lotus Service Notes Section JL Sequence of Operation In the following diagrams, one half of the hydraulic modulator is shown schematically, representing the front brake control circuit, with the sequence of operation described for the left hand front wheel brake. This sequence would be similar for any of the other three wheel brakes.
Page 198 Lotus Service Notes Section JL Pressure Isolation (Pressure Maintain) If signals received from the wheel speed sensors indicate imminent lock up of the LH front wheel, the first step in the 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.
Page 199 Lotus Service Notes Section JL Pressure Reduction Once the LH front wheel brake circuit has been isolated from the master cylinder, the pressure must be reduced in order to allow wheel speed to be restored. This pressure reduction is achieved by the ECM energis- ing the dump valve solenoid, which then opens against spring pressure and bleeds off some of the fluid into the low pressure accumulator shared with the RH front circuit.
Page 200 Lotus Service Notes Section JL Pressure Increase (Re-apply) As soon as imminent wheel lock is detected by the ECM, and the ABS control system is activated, the pump motor is energised. When the dump valve is opened, and fluid is allowed to bleed off from the wheel brake circuit into the low pressure accumulator, this fluid is scavenged by the pump and returned back into the input circuit through an attenuator orifice.
Page 201 Lotus Service Notes Section JL Brake Release When no further wheel locking is sensed by the ECM, the ABS becomes inactive with the isolation valve open (solenoid de-energised) to allow direct communication between the master cylinder and wheel brake circuit, and the 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.
Page 202 16 Nm Bleed the unit of air (see Sub-section JL.3). Verify correct connection by using the ‘Lotus Techcentre’ tool in actuator tests with the car on a wheel free lift. Check that operation of each solenoid valve affects the appropriate wheel.
Page 203 On the Evora, CAN based systems include; engine management, anti-lock braking, safety restraint, instrument pack and tyre pressure monitoring (where fitted). A 'stand alone' lap top PC loaded with 'Lotus TechCentre' software allows the CAN based serial data to be read. Updates and support are accessed via an internet connection.
Page 204 Reading ECM identification. Updating ECM calibration. Important Notes Whenever the Lotus TechCentre tool is connected, the ABS tell tale is lit and the anti-lock function is in- operative. Never connect or disconnect the DLC to/from diagnostic equipment with the ignition switched on.
Page 205 RR REL. SOL. CMD Rear right solenoid release command RR REL. SOL. FDBK Rear right solenoid release feedback 3. ECU Identification Lotus Electro-Hydraulic Unit part number: C132J0007J Bosch Electro-Hydraulic Unit part number: 0 265 236 143 Bosch ECU Software reference: 6209306030000 Page 23...
Page 206 Brake system or electronic control unit malfunction; C0556 Replace electronic control unit; C0561 Replace electronic control unit; C0563 Replace electronic control unit; C0564 Replace electronic control unit; C0800 Switched battery voltage: high (valve relay) low (valve relay) For remedial procedures, see Lotus TechCentre display. Page 24...
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Page 208 Lotus Service Notes Section KJ ENGINE COOLING SECTION KJ Sub-Section Page General Description KJ.1 Maintenance KJ.2 Drain/Refill Procedure KJ.3 Radiator & Cooling Fan KJ.4 Radiator Fan & Re-circ. Pump Control KJ.5 Radiator Feed & Return Pipes KJ.6 Page 1...
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Page 210 Lotus Service Notes Section KJ Thermostat Closed Heater matrix Thermostat closed circuit By-pass flow Throttle body circuit Heat exchanger circuit k76a KJ.1 - GENERAL DESCRIPTION The engine liquid cooling system comprises an engine driven water pump, flow thermostat, front mounted radiator with two electric cooling fans, header tank, re-circulation pump, and associated plumbing.
Page 211 Lotus Service Notes Section KJ panel. A hose from the engine coolant outlet housing feeds the heat exchanger, with a return hose linking to the heater return circuit. When the engine is cold, heat is transferred from the quickly warming coolant to the engine oil, whilst at high engine temperatures, the temperature managed coolant acts to extact heat from the hotter lubrication system.
Page 212 In order to protect against these dangers as well as raising the boiling point of the coolant, the Evora is factory filled with a 50% concentra- tion of Havoline XLC, which is a mono-ethylene glycol coolant using organic acid technology (OAT) to provide increased corrosion protection compared with conventional coolant additives.
Page 213 Lotus Service Notes Section KJ mended coolant mixture (see above) via the header tank. An air bleed plug is located on the heater return hose near its connection with the return rail, and a bleed nipple is incorporated on the by-pass pipe near its joint with the thermostat housing.
Page 214 Lotus Service Notes Section KJ To avoid the requirement to recover the refrigerant, provide alternative support before releasing the 4 fixings securing the a.c. condenser to the radiator; ensure that the a.c. pipes and unions are not stressed. Release the two brackets securing the top of the radiator to the subframe and ease the spigots on the bottom tank from its mounting grommets.
Page 215 Lotus Service Notes Section KJ clamped to the chassis side. Access to the joints at each end of the sill pipes is available with the 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.
Page 216 Lotus Service Notes Section LN FUEL SYSTEM SECTION LN Sub-Section Page General Description LN.1 Fuel Requirement & Filling LN.2 Precautions LN.3 Fuel Pump/Sender Assembly LN.4 Fuel Tank LN.5 Fuel Supply Test LN.6 Charcoal Canister LN.7 Page 1...
Page 217 Lotus Service Notes Section LN Evora Fuel System Layout Fuel pressure Regulator 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...
Page 218 Lotus Service Notes Section LN LN.1 - GENERAL DESCRIPTION The 60 litre fabricated stainless steel fuel tank is mounted within an open bottomed chassis crossmember ahead of the engine bay and beneath the floor of the cabin rear compartment. The fuel filler neck is connected to the RH rear corner of the tank, with a breather connection at the LH front corner, and the pump/gauge sender unit mounted centrally in the front upper surface, accessible via removeable panels in the body floor and chassis.
Page 219 Any of these actions may damage the catalytic converters. Ethanol E5 & E10 - A mixture of 5% or 10% ethanol (grain alcohol) and unleaded petrol may be used in the Evora but the lower octane rating (typically 93 - 94 RON) will result in slightly reduced performance and economy. If driveability problems are experienced as a result of using ethanol, use 95 RON unleaded petrol.
Page 220 Lotus Service Notes Section LN Filler cap parking ohe22 LOTUS Fuel filler flap release button ohe43 Filler Cap: The fuel filler is located in the right hand rear quarter panel, concealed by a flush fitting hinged flap. To open the flap, press the release button in the fascia panel outboard of the steering column, with or without the ignition key in position, and the flap will spring fully open.
Page 221 Lotus Service Notes Section LN If the engine is a non-runner, pull out the fuel pump fuse, and crank the engine for 20 seconds to minimise residual fuel pressure. Disconnect the battery. The hose connecting the fuel tank to the fuel rail has no joints other than the push-on connectors at each of its ends.
Page 222 Lotus Service Notes Section LN depressing the retaining barb behind the resistor block, and sliding the block downwards. 10. Before re-fitting the assembly back into the tank, ensure that all connector plugs are secure, and that the top sealing ring is in good condition. To aid subsequent removal, apply a dab of moS2 grease to each of the retaining studs on the tank before fitting the pump assembly.
Page 223 Lotus Service Notes Section LN LN.6 - FUEL SUPPLY TEST To Test Fuel Pump Output Fuel pressure is controlled by the fuel pump and pressure regulator valve. Delivery may be checked at the connection to the fuel rail after de-pressurising the system and using a proprietary fuel pressure gauge.
Page 224 Lotus Service Notes Section LN press button quickfit connector to join to the mid-positioned spigot on the canister marked 'TANK', within which the port is extended to the far end of the charcoal bed. In this way, vapour from the fuel tank is cleansed of fuel by the charcoal bed before being vented.
Page 225 Lotus Service Notes Section MR ELECTRICS SECTION MR Sub-Section Page PFK 457 Vehicle Security Alarm MR.1 Central Door Locking MR.2 Electric Windows MR.3 Door Mirrors MR.4 Switches & Instruments - Driver's Information MR.5 Component Location & Fuse Ratings MR.6 Audio Equipment MR.7...
Page 226 PIN will allow the security system to be overridden in case of transmit- ter loss or failure (see later). Vehicle Security Alarm The Lotus Evora is fitted as standard with a PFK 457 immobiliser/alarm which includes the following features: •...
Page 227 Lotus Service Notes Section MR Auto Re-arm If a door is not opened and closed within 2 minutes of a disarming command, the doors will passively re- lock and the alarm system re-arm. Passive Immobilisation In order to provide a measure of automatic vehicle security, independent of any driver initiative, the system will automatically immobilise the engine’s cranking and fuel pump circuits after the ignition has been turned off...
Page 228 Lotus Service Notes Section MR Turning Off the Interior Movement Sensor A microwave sensor mounted behind the centre console, will detect substantial physical movement within the cockpit, and trigger the alarm. If an animal is to be left in the vehicle, or if for any other reason it is desired to exclude the interior move- ment sensor, press once the transmitter logo button in the normal way to set the alarm, and then press a second time (within 2 seconds) to exclude the interior movement sensor.
Page 229 Lotus Service Notes Section MR Turn off the ignition and after a number of flashes corresponding to the second digit of the PIN, turn on the ignition. Repeat this process until all 5 digits have been completed. If, at any stage of the process, a number is entered incorrectly, the system will immediately revert to the start, so that the whole PIN must be re-entered.
Page 230 Lotus Service Notes Section MR Trigger report back: After the code 12311 has been entered, the tell tale flashes out a code(s) to indicate the source of the alarm trigger: No. of flashes Triggering sensor Microwave movement sensor Door, bonnet or boot lid...
Page 231 Lotus Service Notes Section MR Note that the lighting up of the interior door locking switch provides a visual indication of the door lock status (locked when lit). WARNING: Whether locked using the locking switch, sill buttons or ‘drive away locking’ feature, the interior release handles will be disabled.
Page 232 Lotus Service Notes Section MR The electric window lift mechanism uses an electric motor and winder drum driving a steel cable around top and bottom guide pulleys to a lift block. The window glass is fixed to the lift block which is guided by a vertical rail.
Page 233 Lotus Service Notes Section MR Blank page Page 9...
Page 234 Lotus Service Notes Section MR MR.5 - SWITCHES & INSTRUMENTS - DRIVER'S INFORMATION Ignition Switch/Steering Lock Column unlocked; The switch/lock is located on the right Key insert/remove; accessories hand side of the steering column. With the audio key out of the switch, the steering column is Ignition;...
Page 235 Lotus Service Notes Section MR TELL TALE LAMPS High engine speed Security Tell tale lamps are incorporated into the instrument panel to provide important informa- tion about various vehicle systems. LOTUS TELL TALE LAMPS ohe3 Bulb Check In order to check that the warning systems are functional, all operative tell tale lamps will light for a few seconds each time the ignition is switched on - refer to the text below for details of this feature relating to par- ticular lamps.
Page 236 (amber) The Engine Control Module (ECM) on the Evora is also used to manage various related electrical systems, and is able to detect certain types of fault, which may or may not be apparent to the driver. If such a fault is...
Page 237 Lotus Service Notes Section MR Traction Control should aways be active when driving on public roads in normal conditions. To re-activate LTC, LOTUS press momentarily the LTC off switch and check that the tell tale is extinguished. For LTC details, see later.
Page 238 As a bulb check, the tell tale will light for about six seconds following igni- tion switch on, and then go out, but if the lamp remains lit, or comes on at any other time, a fault in the airbag system is indicated, which should be rectified without delay by your Lotus dealer. INSTRUMENTS...
Page 239 Lotus Service Notes Section MR Fuel Level Display An indication of the level of fuel in the tank is displayed, with ignition on, in the form of a vertical bar graph in the instrument panel left hand screen. The solid bar within the outline, represents the proportion of fuel remaining in the tank.
Page 240 Lotus Service Notes Section MR Ambient temperature units Current temperature display units will now be displayed. To change from °C to °F, or vice-versa, press momentarily the info. button. To retain the displayed units, press the info. button for more than one second to enter the next mode: Tyre pressure units (if TPMS is fitted) Current tyre pressure units will now be displayed.
Page 241 Lotus Service Notes Section MR Tyre Pressure Monitoring System (TPMS) On cars so equipped, a sensor incorporated into each of the tyre valves, monitors the air pressure inside the tyre, and supplies an onboard control module with this data by radio transmission. As soon as the car has been driven a short distance, tyre pressure readings will be displayed against the corresponding wheels on the vehicle silhouette in the instrument cluster right hand screen.
Page 242 Lotus Service Notes Section MR ‘Lights On’ Warning If the lights are on when the ignition is switched off, a ‘lights on’ audible warning will sound when the driver’s door is opened. Rear Fog Lamp Switch (where fitted) The lowermost outboard switch controls the single rear fog lamp, which will operate only when both the ignition and the headlamps are active. The switch button symbol is backlit red with the sidelamps on, and lights...
Page 243 Lotus Service Notes Section MR Steering Column Lever Switches Lever switches are provided on the steering column, one on the left for headlamp functions, and one on the right for windscreen wiping and washing. Right turn ohe2 ohe2 Fast wipe...
Page 244 Passenger Airbag Defeat (PAB) Switch PASSENGER If a rearward facing child seat is to be AIRBAG used in the front passenger seat of the Evora, SWITCH it is essential to switch off the passenger air- (RHD shown) bag. If an accident should occur and trigger...
Page 245 6,600 to 7,000 rpm. Note that switching off the Lotus Traction Control (see above) in conjunction with selection of Sport Mode, will retain the Sport features, but without any power induced wheelslip intervention. In all cases, anti-lock braking will be retained.
Page 246 Lotus Service Notes Section MR Briefly pressing the button a second time will switch off Sport Mode as soon as the throttle pedal is fully released. Note that Sport Mode will default to ‘off’ at the next ignition cycle. Cruise Control The cruise control system is operated by four switches mounted on the steering wheel Set/raise spokes.
Page 247 Lotus Service Notes Section MR MR.6 - COMPONENT LOCATION & FUSE RATINGS Main Fusebox The main fuse and relay boxes are located at the front of the passenger footwell, protected by a removable panel secured by a quarter turn fastener at each top corner, and a location channel on the floor. Forty slots are provided for mini fuses which are numbered, and coloured according to their amperage rating, and may be pulled out from their slots using the fuse extractor tool clipped to the fusebox.
Page 248 Lotus Service Notes Section MR Front Relay Blocks Mounted on the front fusebox panel, is a block of relays, the layout of which is inverted for opposite drive hands: Integrated 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.
Page 249 Lotus Service Notes Section MR Key to ICM Diagram Description Description Supply for indicator relays Main beam flash power input Left indicators output Int. fan fast input Fog switch illum. input Fog switch input Drive away locking output Sidelights switch illum. output...
Page 250 Lotus Service Notes Section MR Rear Fusebox Fuses and relays for the engine bay and rear mounted systems are contained in a fusebox mounted in the cabin, behind the left hand rear quarter trim panel. For access, use a coin to release the quarter turn fastener on the lower edge of the removable panel, and unhook the top edge.
Page 251 Lotus Service Notes Section MR Component Location Other electrical components may be found as follows: CDL module; passenger side of scuttle beam vertical face. Alarm components; see sub-section MR.1. Horns; one beneath the front end of each front longeron, aligned with apertures in the air intake duct. Accessible after removal of front undertray. Ambient air temperature sensor; mounted in RH side of the air intake duct, clipped to the undertray pylon. Accessible after removal of front undertray. Audio speaker cross-over units; one on each end of the scuttle vertical rear face. Forward crash sensor; one on the outboard face of each front subframe longeron, towards the front. Ac- cessible after removal of the front undertray.
Page 252 Under conditions of normal daily use, it should not be necessary to use external battery charging equip- ment. In a low usage regime, however, it is important to maintain the charge state of the battery using a trickle charger, or an automatic battery management conditioner such as that available through Lotus After Sales. Page 28...
Page 253 Lotus Service Notes Section MR Starting difficulties may be encountered after an unattended period of 3 weeks. A battery conditioner is able to continuously monitor battery charge state and switch on and off automatically in order to maintain the battery in a fully charged condition without danger of damage through overcharging.
Page 254 Lotus Service Notes Section MR To remove the wiper mechanism: Remove the front clamshell (see sub-section BV.4). Remove the wiper arm. Remove the 4 retaining screws, and withdraw the windscreen gutter with drain tubes. Unplug the harness connector from the wiper motor. Release the 4 cap head screws around the wiper spindle that secure the mounting bracket to the windscreen frame, and the single screw at the motor end of the bracket.
Page 255 Other serviceable parts may be replaced after removing the headlamp housing from the car. Halogen Bulb Headlamp Assemblies The Evora is also available with halogen bulb headlamp assemblies, which share the same housing and features of the Xenon units, but are replace the HID headlamp equipment with a simpler H4 halogen bulb.
Page 256 Lotus Service Notes Section MR When re-fitting, ensure the front clamshell is first fitted and optimised for position before adjusting the headlamp mounting to obtain a satisfactory fit of the lamp in the aperture. Re-connect the harness and washer tubing and check headlamp beam alignment.
Page 257 Lotus Service Notes Section MR the headlamp assemblies. These lamps are designed for long life and are serviceable only by replacement of the complete headlamp unit. Rear Lamp Cluster Bulbs The outboard lamp cluster contains the tail, brake and turn indicator functions, and is configured as fol- lows: Annulus; tail and brake lamps.
Page 258 Lotus Service Notes Section MR MR.14 - CIRCUIT DIAGRAMS Circuit Sheet Page Battery Supply Accessory Key In Accessory Supply Ignition Supply Charging System CAN Network Diagnostic Link Connector Grounding Structure Cranking Alarm & Immobiliser Central Locking Fuel Filler Flap & Glovebox Solenoids EMS Power &...
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Page 308 Lotus Service Notes Section OK MAINTENANCE & LUBRICATION SECTION OK Page Recommended Lubricants Maintenance Schedule Pre-Delivery Inspection Pre-Delivery Paint Mark Up Licence Plate Fitment Page 1...
Page 309 Note that no oil additives are approved by Lotus. Viscosity: ambient above -20°C...
Page 310 Lotus Service Notes Section OK 'Severe Service’ Conditions Certain operating conditions can cause rapid degradation of the oil quality, either by the accumulation of dirt particles, or by the absorption of water from condensation. If any of the ‘severe service’ conditions de- scribed below apply, it is recommended that the oil and filter be changed twice as frequently as is listed in the Maintenance Schedule.
Page 311 MANNER, INCLUDING TIMED LAPS OR RUNS. ANY SUCH USE WILL INVALIDATE THE NEW VEHICLE WARRANTY. If an owner elects to use the Evora on a closed circuit track or in a competitive manner, the severity of operating conditions demands that appropriate levels of expert car preparation, servicing (over and above that specified in the Maintenance Schedule) and vigilance will be required, including careful inspection of all safety critical components both before and after any track or competition session.
Page 312 Inspect auxiliary drive belt condition 10 Inspect integrity of fuel system 11 Inspect for fault codes & ECU programme level 12 Print Engine History & Performance reports and return to Lotus Cooling System Inspect water radiator & pipework for damage or leaks. Clean...
Page 313 Lotus Service Notes Section OK Road Test Performance Engine performance ......…....Tailpipe CO ............Clutch operation ............Gearbox operation ..........Brake performance ........... Steering performance ........... Driveline & suspension noise/vibration ....... Wheel balance ............General comments …………………………………………………………………………………………………… ......................………………………..... ………………………………………………………………………………………………………………………….. Additional Work Performed or Required …………………………………………………………………………………………………………………………..
Page 314 Inspect seat adjustment latching & operation of front & rear seatbelts. Inspect interior trim for damage & cleanliness. Inspect all paint work for damage (Elise LSL407a; Exige LSL409a; Europa LSL514; Evora LSL544). Check presence of toolkit & literature pack. Fit number plates and tax disc holder.
Page 315 All costs incurred during the inspection process are the res- ponsibility of the dealer. c) Failure to return a signed copy of this inspection to Lotus Cars Ltd. by the dealer, may result in warranty claims on the particular car being rejected.
Page 316 Lotus Service Notes Section OK PRE-DELIVERY PAINT MARK UP - EVORA lsl544 PAINT DEFECT CODE B BLISTERING N SHADING C CHIPS O OVERSPRAY COLOUR D DISTORTION P PRE-RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES OWNER H PIN HOLES...
Page 317 Lotus Service Notes Section OK Licence Plate Fitment Front The mounting plinth for the front licence plate is screw fixed to the front clamshell, and is slightly curved in plan. Typically, the plate is secured using double sided tape in conjunction with two fixing screws with suitable blind fix nuts (e.g.
Page 318 Lotus Service Notes Section PN AIR CONDITIONING, HEATING & VENTILATION SECTION PN Sub-Section Page General Description PN.1 Heater/A.C. Airflow Overview PN.2 Cooling Fans & Re-circulation Pump PN.3 Refrigerant Handling PN.4 Refrigerant Pipework Precautions PN.5 Refrigerant Oil PN.6 Compressor PN.7 Condenser PN.8...
Page 319 Lotus Service Notes Section PN 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 Refrigerant Circuit Expansion valve High pressure vapour line...
Page 320 Lotus Service Notes Section PN PN.1 - GENERAL DESCRIPTION The heating, ventilation and air conditioning (HVAC) main unit comprises a plastic casing secured to the front face of the main chassis tub, housing the fan blower, a.c. evaporator and heater matrix, with a fresh air inlet adaptor on its top face, a re-circulation intake port on the rear face, and an outlet to the air distribution chamber on the top rear of the unit.
Page 321 Lotus Service Notes Section PN Compressor The variable displacement compressor is mounted on the front side of the engine, and is driven by the multi-rib auxiliary belt. The compressor operates to discharge refrigerant vapour at high pressure and tem- perature into the condenser and is lubricated by a quantity of special refrigerant oil, most of which is retained in the compressor, with the remainder being circulated with the refrigerant.
Page 322 Lotus Service Notes Section PN Evaporator The evaporator is a 'serpentine' type heat exchanger mounted within the HVAC unit. The low pressure liquid refrigerant flowing into the evaporator via the expansion valve, begins to boil (evaporate) and in so doing, draws the necessary heat for this process from the airstream passing across the evaporator finning.
Page 323 Lotus Service Notes Section PN Ambient air collected from the top of the intake duct, ahead of the engine radiator, is fed via an insulated fibreform duct to a pollen filter mounted at the intake to the HVAC unit, within which the airflow is divided towards the inner and outer sides of the two blower fans.
Page 324 Lotus Service Notes Section PN Face level vents & footwells To face level vent ducting in underside of fascia top panel Airflow from HVAC unit To footwell vents Footwell vents Airflow from HVAC unit To footwell vents Footwells & windscreen...
Page 325 Lotus Service Notes Section PN Windscreen To windscreen vent ducting in underside of fascia top panel Airflow from HVAC unit Temperature Control The rotary temperature control actuates the air blender flap, which dictates the proportion of the airflow which is directed through the heater matrix. With the control knob fully clockwise at the coldest position, the heater matrix is fully shut off.
Page 326 Lotus Service Notes Section PN The interior fan will operate at full speed; All airflow will be directed to the windscreen; Air conditioning will be switched on (may be overridden by manual de-selection). Note that an appropriate temperature setting must be selected manually.
Page 327 Lotus Service Notes Section PN Re-circulation Pump A coolant re-circulation electric pump is mounted beneath the air cleaner, and is plumbed into the heater supply line. When energised, the pump circulates coolant through the heater system, drawing coolant from the back of the cylinder head, and pumping it through the heater matrix and back to the engine.
Page 328 Lotus Service Notes Section PN Refrigerant Pipework Fixing Torques Description Thread Pitch Torque Compressor to engine 25 Nm A.C. hoses to compressor 9 Nm Sill pipe to comp. hose, high pressure 3/4 - 16 UNF 25-30 Nm Sill pipe to comp. hose, low pressure...
Page 329 Lotus Service Notes Section PN All joints should be coated with refrigeration oil before making any connections, to aid seating. Great care must be taken to prevent damage to the pipe fittings and connections, since due to the high pressures involved, a leak can be caused by the slightest imperfection. Always use two spanners of the correct size when releasing or tightening any pipe joint so that the fixed part of the union may be prevented from twisting and damaging the component.
Page 330 Lotus Service Notes Section PN Release the clamp plate securing each of the pipes to the compressor and immediately cap the pipes and compressor ports to prevent ingress of dirt and moisture. Secure the two pipe/hoses aside. Disconnect the two compressor electrical harness plugs.
Page 331 Lotus Service Notes Section PN Compressor Fitment Fit the compressor to the engine and secure with the three M8 bolts; Tighten to 25 Nm (18 lbf.ft). Using new 'O' rings lubricated with mineral refrigerant oil, fit the two refrigerant pipes to the compressor and tighten each clamp plate screw to 8 Nm.
Page 332 Lotus Service Notes Section PN PN.9 - RECEIVER-DRIER If the system has been open to atmosphere for any length of time, e.g. following accident damage or a burst hose or damaged component, the receiver-drier unit must be renewed, and should be the last component to be fitted, and uncapped only immediately prior to connection and recharging.
Page 333 Lotus Service Notes Section PN Outlet to compresser Inlet from receiver-drier M6 clamp screw 'O' ring seal Top clamp plate M5 clamp screw (x2) Expansion valve body Lower clamp plate (tapped) 'O' ring seal Evaporator outlet pipe Evaporator inlet pipe Refit the HVAC unit in reverse order to removal: - If a new evaporator is fitted, add 30 cm³...
Page 334 Lotus Service Notes Section PN PN.12 - REFRIGERANT PIPES The main feed and return (high pressure liquid and low pressure suction) lines between the compressor, condenser 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.
Page 335 Lotus Service Notes Section QJ CLUTCH SECTION QJ Sub-Section Page General Description QJ.1 Clutch Pedal QJ.2 Hydraulic Release System QJ.3 Clutch Assembly QJ.4 Page 1...
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Page 337 QJ.1 - GENERAL DESCRIPTION The Lotus Evora uses a CMS C500 cast iron flywheel bolted to the rear end of the engine crankshaft, secured with 8 bolts and located by a dowel pin. Sandwiched between the flywheel and crankshaft is a steel plate carrying the starter ring gear, and also secured to the periphery of the flywheel with 6 screws.
Page 338 Lotus Service Notes Section QJ Illustration TBA To refit, reverse the removal procedure. Tighten the outlet pipe connection to 20 - 24 Nm, and the cylin- der to pedal box fixings to 28 Nm. Bleed the hydraulic system of air, using the bleed nipple provided on the slave cylinder.
Page 339 Lotus Service Notes Section QJ QJ.4 - CLUTCH ASSEMBLY The clutch assembly comprises the friction plate, clutch cover assembly (pressure plate/diaphragm spring/ cover) and release bearing. For access to the clutch assembly, the complete power unit must first be removed from the chassis (see sub-section EJ.5).
Page 340 Lotus Service Notes Section TDT TECHNICAL DATA - ENGINE SECTION TDT Page General ....................... Cylinder Block ..................... Cylinder Head ...................... Valves & Springs ....................Camshafts ......................Pistons ........................ Crankshaft ......................Oil Pump ......................Coolant Thermostat .................... Page 1...
Page 341 Lotus Service Notes Section TDT GENEral Type designation 2Gr-FE Configuration Capacity 3456 cm³ (210.9 in Bore 94.0 mm (3.70 in Stroke 83.0 mm (3.27 in Valve configuration 4 VPC in pentroof chamber Camshaft configuration DOHC per bank Camshaft drive Single chain drive to both inlet camshafts.
Page 342 Lotus Service Notes Section TDT CylINDEr HEaD Material aluminium alloy Head face flatness tolerance 0.10 mm (0.004 in.) Manifold face flatness tolerance 0.10 mm (0.004 in.) Valve guide bore in head - std 10.285 to 10.306 mm (0.4049 to 0.4057 in.) - 05mm o/s 10.335 to 10.356 mm (0.4069 to 0.4077 in.)
Page 343 Lotus Service Notes Section TDT COOlaNT THErMOSTaT Valve opening temperature 80 to 84°C (176 to 183°F) Valve lift at 95°C 10 mm Page 4...
Page 344 Lotus Service Notes Section TDU TECHNICAL DATA - VEHICLE SECTION TDU Page Dimensions ......................Capacities ......................Wheels & Tyres ....................Front Suspension ....................Rear Suspension ....................Electrical ......................Transmission ....................... Clutch ........................Brakes ......................... Steering ....................... Fuel Consumption ....................Page 1...
Page 345 2.3 bar (33 lb/in²) - rear 2.5 bar (36 lb/in²) Tyre studding Not permitted Tyre chains RUD-matic DISC snow chains (Lotus part number A132G6004F), fitted only on the rear, and only on the approved winter tyres. Wheels Type - std...
Page 346 Lotus Service Notes Section TDU Size - front 8.0J x 18H2 - rear 9.5J x 19H2 Inset - front + 52 mm - rear + 69 mm Wheel bolt torque 105 Nm (77 lbf.ft) FRONT SUSPENSION Type Independent. Upper and lower lightweight forged alloy wishbones;...
Page 347 Lotus Service Notes Section TDU TRANSMISSION Designation 6 speed manual type EA60 Differential Open bevel gear Gear ratio table ('opt' refers to alternative ratio set) Gear Internal ratio Final drive mph/1000rpm km/h/1000rpm 3.54 3.78 1.91 3.78 10.4 16.7 1.22 3.78 16.3...
Page 348 Lotus Service Notes Section VE INTERIOR TRIM SECTION VE Sub-Section Page General Description VE.1 Door Trim Panel VE.2 Door Trim Panel Components VE.3 Door Sill Trim Panel VE.4 Lower 'A' Post Trim Panel VE.5 Centre Console VE.6 Fascia Dash Panel VE.7...
Page 349 Lotus Service Notes Section VE Page 2...
Page 350 Lotus Service Notes Section VE VE.1 - GENERAL DESCRIPTION Interior trim panels on the Evora are manufactured by one of three processes; Structural Reaction Injection Moulding (SRIM); using a polyurethane resin and glass reinforcement. Panels include: - Door trim panels;...
Page 351 Lotus Service Notes Section VE The door trim panel is secured to the door shell by the door pull handle fixings, five screws along the bot- tom shutface, a single screw at the top front corner, and three location pegs along the top edge. Note that the door speaker grille is fixed to the door panel, but the speaker itself is mounted to the door shell.
Page 352 Remove the parking brake lever sleeve after loosening the retaining grub screw. Prise the Lotus badge from the gear lever knob, release the screw and withdraw the knob. Release the armrest from its hinge by removing the two fixings beneath its rear end.
Page 353 Lotus Service Notes Section VE Open the glovebox, and from within, release the 4 hex. head screws securing the fascia panel finisher to the glovebox wall. Withdraw the dash panel, and unplug the harness connectors to the mood lighting strip and glovebox light.
Page 354 Lotus Service Notes Section VE VE.11 - WINDSCREEN PILLAR TRIM PANELS Each windscreen pillar trim panel is retained by a single 'fir tree' button at its lower end, and by 3 captive 'fir trees' along its length. VE.12 - REAR QUARTER PANELS...
Page 355 Lotus Service Notes Section VE VE.14 - REAR WINDOW SURROUND The rear window surround is secured by four spring clips. Pull the panel forwards to remove. VE.15 - ROOF LINING The roof lining is retained by the sun visor brackets, the 'B' post upper trims, and two screws at the rear edge.
Page 356 Lotus Service Notes Section WF AIRBAG SYSTEM SECTION WF Sub-Section Page General Description WF.1 Airbag Tell Tale WF.2 Data Link Connector WF.3 Trouble Codes WF.4 Lotus TechCentre WF.5 Safety Precautions, Shipping, Storage & Disposal WF.6 Theory of Operation WF.7 Sensor & Diagnostic Module (SDM) WF.8...
Page 357 Lotus Service Notes Section WF Illustration to follow Page 2...
Page 358 Passenger Airbag Defeat (PAB) Switch If a rearward facing child seat is to be used in the front passenger seat of the Evora, it is essential to switch off the passenger airbag. If an accident should occur and trigger airbag inflation, the back of the seat could be subjected to a force sufficient to seriously injure or kill the child.
Page 359 On the Evora, CAN based systems include; engine management system, instrument pack, tyre pressure moni- toring and ABS/Traction Control/ESP. A CAN compliant on-board diagnostic system is accessible via a 'stand alone' lap top PC loaded with 'Lotus TechCentre' software to allow the CAN based serial data to be read. A Vehicle Communication Device (VCD;...
Page 360 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 mounting to the Evora.
Page 361 U.S. Dept, of Transportation (DOT) and most state governments. Special procedures are required for transportation. Lotus recommends that the dealers and repair shops check with the hazardous material section of their respective state police authority for applicable shipping requirements.
Page 362 Lotus Service Notes Section WF Deployed Inflator Modules WARNING: Safety precautions must be observed when handling a deployed inflator module. After de- ployment, the air bag surface may contain a white packing powder used to ease deployment. Always wear gloves and safety glasses when handling a deployed inflator module, and wash your hands with a mild soap and water afterwards.
Page 363 Lotus Service Notes Section WF tensioners. • In case of a required deployment, timely switching of the activation current for the deployment loops. • Detection of electrical system faults which may influence the readiness of the system to deploy, or increase the probability of an inadvertent deployment by: - continuous electrical monitoring of all deployment circuits (without any effect on the readiness of the system); - continuous monitoring of the supply voltage and the lamp circuitry (dependent on lamp driver activation status);...
Page 364 Lotus Service Notes Section WF The tell tale will be activated without SDM intervention in the following situations: • the minimum voltage of 8.0 V has not been exceeded after switching on the ignition. • the energy reserve (in SDM) has run low, which may be caused by supply voltages below 7.8 V. • the watchdog has interfered. A trouble code readout using tell tale blink codes is not implemented. Power Supply & Grounding The nominal supply voltage of +12 volts is derived from terminal 5 when the ignition is switched on.
Page 365 Lotus Service Notes Section WF WF.9 - DRIVER AIRBAG MODULE WARNING: Safety precautions must be observed when handling a deployed airbag. After deployment, the airbag surface may contain a white packing powder used to ease deployment. Always wear gloves and safety glasses when handling a deployed inflator module, and wash your hands with a mild soap and water afterwards.
Page 366 Lotus Service Notes Section WF When all service work is complete, connect the harness plugs to the rotary connector sockets and refit the column shrouds. Reconnect the battery, turn on the ignition and check that the airbag tell tale lights for a few seconds and then goes out.
Page 367 Turn off the ignition. ii). Before disconnecting the battery, use the Lotus TechCentre to read any stored trouble codes. iii). Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the battery negative terminal can be made.
Page 368 Lotus Service Notes Section WF WARNING: Proper operation of the SRS system requires that the vehicle structure remains in its origi- nal production configuration. Any damage to the SRS components and/or their respective mounting brackets, including the chassis, requires replacement, not repair.
Page 369 Lotus Service Notes Section WF The belt pre-tensioning mechanism is designed to operate only once, such that both front belt assemblies should be renewed after airbag/seat belt pre-tensioner deployment. Activation of the pyrotechnic mechanism is indicated by the belt reel being locked, and allowing neither extraction nor retraction of the belt.
Page 370 WARNING: The seat belt pre-tensioner devices fitted on the Lotus Evora are designed and calibrated specifically for this particular model. Pre-tensioners must not be adapted, re-used or installed on any other vehicle - they must only be fitted to the prescribed vehicle with specific homologation continu- ity.

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