Page 1 Lotus Service Notes Introduction CONTENTS ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ ENGINE Section Technical Data - Engine - Vehicle Chassis Bodycare & Repair Body Fittings Front Suspension Rear Suspension Engine & Engine Management - Lotus supplement - Toyota 1ZZ/2ZZ engine repair manual...
Page 2 '2004 M.Y. onwards Assembly Plant Model Vehicle Type H = Hethel 2 = 2-Eleven Manufacturer Check 111 = Elise B = Shah 3 = Elise Identiﬁer Code 123 = 2-Eleven Digit Alam 8 = Exige S C C 1 2 3...
Page 3 2005 M.Y. Elise for North America: May 2004 VIN character 10 = 5; Character 12 = L; Serial number from 0001 Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for those models later in the year.
Page 4 LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC duct- ing. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but ﬁxed valve lift, plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within standard trims.
Page 5 Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black nosebadge, gold fuel ﬁller cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspen- sion.
Page 6 Lotus Service Notes Introduction ENGINE BAY UNDERTRAY/DIFFUSER For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser panel. The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay clean.
Page 7 Lotus Service Notes Introduction JACKING POINTS Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a 4-point lift is to be used, the engine bay undertray/diffuser panel (if ﬁtted) must ﬁrst be removed.
Page 8: Table Of Contents
Lotus Service Notes Section TDP TECHNICAL DATA - ENGINE SECTION TDP Page General ........................Cylinder Block ......................Cylinder Head ......................Valves & Springs ...................... Camshafts ........................ Pistons ........................Connecting Rods ...................... Crankshaft ....................... Oil Pump ........................Coolant Thermostat ....................Page 1 sn_tdp_engine_cyclone.indd 1...
Page 9: General
Lotus Service Notes Section TDP GENERAL Type designation - All except Elise S 2ZZ-GE 1ZZ-FE - Elise S Conﬁguration & no. of cylinders in-line 4 Capacity 1796 cm 1794 cm³ Bore 82.00 mm 79.00 mm Stroke 85.00 mm 91.50 mm...
Page 10: Cylinder Head
Lotus Service Notes Section TDP CYLINDER HEAD 2ZZ-GE 1ZZ-FE Material Aluminium alloy Head face ﬂatness tolerance 0.05 mm Reface limit No machining VALVES & SPRINGS Valve seat angle in head 45° Valve face angle 44.5° Cold valve clearance (between cam & follower) - inlet 0.10 - 0.16 mm...
Page 11 Lotus Service Notes Section TDP Page 4 sn_tdp_engine_cyclone.indd 4 03/07/2006 14:59:41...
Page 12 Lotus Service Notes Section TDP Page 5 sn_tdp_engine_cyclone.indd 5 03/07/2006 14:59:41...
Page 13 Lotus Service Notes Section TDQ TECHNICAL DATA - VEHICLE SECTION TDQ Page Dimensions ......................2 Capacities ......................2 Wheels & Tyres ....................3 Front Suspension ....................3 Rear Suspension ....................4 Electrical ......................5 Transmission ....................... 5 Clutch ........................6 Brakes .........................
Page 14: Dimensions
702 mm - Exige 692 mm Approach angle (at kerb) 13.5° Departure angle (at kerb) 23° Unladen weight - 111R/Elise R - total 860 kg > (lightest) - front 327 kg > incl. full fuel tank - rear 533 kg >...
Page 15: Wheels & Tyres
12 ° nominal Geometry specification - Standard Elise: Mid-laden ride height (reference height for geometry check) - USA Elise from VIN 3013 & 111R/R/S- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail...
Page 16: Rear Suspension
Geometry specification - Standard Elise: Mid-laden ride height (reference height for geometry check) - USA Elise from VIN 3013 & 111R/R/S- front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail...
Page 17: Electrical
- all except Elise S 6-speed manual incl. final drive - Elise S 5-speed manual incl. final drive Differential - standard Open, bevel gear - option Torsen type LSD with Lotus Traction Control Gear Ratio Final Drive mph(km/h)/1000 rpm 5-speed 6-speed 5-speed...
Page 18 Lotus Service Notes Section TDQ CLUTCH Type Single dry plate. Diaphragm spring cover. Hydraulic release. Friction plate diameter 215 mm Diaphragm finger clearance 1.00 mm Diaphragm finger height - new 37.5 - 32.1 mm - service limit 42.75 mm Friction plate thickness - new 7.4 - 6.9 mm...
Page 19 Lotus Service Notes Section AH CHASSIS SECTION AH Sub-Section Page General Description AH.1 Chassis Straightness Check AH.2 Rear Subframe AH.3 Page 1 sn_ah_cyclone.indd 1 03/03/2006 10:51:12...
Page 20 Lotus Service Notes Section AH Page 2 sn_ah_cyclone.indd 2 03/03/2006 10:51:13...
Page 21 Section AH AH.1 - GENERAL DESCRIPTION The chassis frame of the Lotus Elise is constructed primarily from aluminium alloy extrusions and formed alloy sheet, with the various sections bonded together using an epoxy adhesive with secondary drive-in fasten- ers. The basic chassis unit includes the passenger cell, front suspension mountings, fuel tank housing, and mid mounted engine bay, with a fabricated sheet steel rear subframe bolting to the rear of the engine bay to provide rear suspension mountings and rear body support.
Page 22 Lotus Service Notes Section AH AH.2 - CHASSIS STRAIGHTNESS CHECK In the absence of visual damage, the chassis may be checked for twist or distortion by utilising the tooling holes in the underside of the main side rails. If computer processed laser measuring equipment is not avail- able, manual checks can be made with reference to an accurately level ground plane, e.g.
Page 23 Lotus Service Notes Section AH AH.3 - REAR SUBFRAME The rear ends of the chassis siderails are linked by a fabricated sheet steel subframe which provides mountings for the rear body section, rear suspension pivots, engine rear stabiliser, exhaust mufﬂer and seat belt mounting frame struts.
Page 24 Lotus Service Notes Section BQ BODYCARE & REPAIR SECTION BQ Sub-Section Page General Description BQ.1 Lotus Composite Body Features BQ.2 Bodycare BQ.3 Accident Damage Assessment BQ.4 Body Panel Bonding Materials BQ.5 Replacement of Bonded-On Panels - General BQ.6 Front Crash Structure BQ.7...
Page 25 Lotus Service Notes Section BQ Body Panels Door shell Windscreen Sill panel Front access frame panel Rear window shroud Engine cover lid Front clamshell Cabin rear Door hinge bulkhead cover panel Rear clamshell Front crash structure Chassis frame b277b Page 2 sn_bq_cyclone.indd 2...
Page 26 Section BQ BQ.1 - GENERAL DESCRIPTION The body panels of the Lotus Elise are constructed of composite materials, with the external panels not being required to contribute to chassis rigidity. The panels are attached to the aluminium chassis and/or other body panels either by elastomeric polyurethane adhesive, or in the case of the front and rear clamshells, are bolted on for ease of dis-assembly and access to chassis parts.
Page 27 BQ.3 - BODYCARE The acrylic enamel paint ﬁnish of the Elise is extremely resistant to all normal forms of atmospheric attack. Following the simple maintenance procedure summarised below will help retain the gloss, colour and protective properties of the paint throughout the life of the vehicle. However, car ﬁnishes are not immune to damage, and amongst the more common causes of deterioration are: Atmospheric contaminants;...
Page 28 Lotus Service Notes Section BQ enced in handling this type of fabric as discoloration and degradation of the special protective inner layer may result. The application of wax ﬁnishes, dressings or preservatives will cause stains which are difﬁcult to remove and therefore should be avoided.
Page 29 & re-activator: Betawipe 4000 Lotus part no. A082B6355V Adhesive: Betaseal 1701 Lotus part no. A082B6281 F or Betamate E2400 Lotus part no. A082B8415V Applicator Bottle An applicator bottle is available for use with some cleaners and primers, and has a disposable felt pad...
Page 30 Lotus Service Notes Section BQ - 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 31 Lotus Service Notes Section BQ BETAPRIME 5404 (A082B6337V) Description: Adhesion promotor used to maximise the performance of the bonding between the cleaned and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium container with RED coloured cap. Application: - Two steel balls inside the container are provided to assist mixing of the contents when shaken.
Page 32 Lotus Service Notes Section BQ BETAMATE E2400 (A082B8415V - 220ml, A100B6258V - 450ml) Description: Two component chemically curing adhesive, providing high strength, permanently elastic bonds between various substrates. Supplied in 220 and 450 ml aluminium cartridges. Application: - An electrically driven Betagun Mk 11 is required to mix and extrude Betamate E2400. Refer to the operating instructions supplied with the gun.
Page 33 Lotus Service Notes Section BQ Operating handle Compressed air inlet Vibrating cutting blade bj46 It is not generally practical to remove a bonded panel intact, for later reﬁtment. Consequently, when necessary, the panel can be cut away for better access to the bonded joint. It is not necessary to remove all traces of sealant from the joint faces on the remaining panels or chassis, but any remaining sealant must be securely bonded and no thicker than 1 mm or the ﬁt and joint gaps will be upset.
Page 34 Lotus Service Notes Section BQ To remove the crash structure: Remove the front clamshell (see sub-section BR.5). Remove the front undershield by releasing the three screws securing each lower side of the structure to the shield, and the three screws securing the shield to the front lower edge of the chassis.
Page 35 Lotus Service Notes Section BQ Application of adhesive bead Betaseal bead b279 Apply a bead of Betaseal/mate adhesive (see sub-section BQ.5) to the bonding surface in the manner shown. Fit the structure to the chassis and press into position to spread the adhesive. Use several clamps around the joint ﬂange to retain the structure until the adhesive has cured;...
Page 36 Lotus Service Notes Section BQ The shape of the frame is critical to the windscreen ﬁt, and structural repairs to the frame itself are not recommended. It is not generally economic to attempt to remove the windscreen frame intact for reﬁtment, as the elastomeric adhesive bonding the frame to the chassis requires cutting with a reciprocating knife, and access to the joints is sometimes obscured.
Page 37 Lotus Service Notes Section BQ To ﬁt a new dash bafﬂe: - Ensure the heater feed and return pipes are ﬁtted. - Dry ﬁt the panel and mark up the bonding surface on the chassis scuttle. - Prepare and re-activate the surface of the old adhesive on the chassis using Betawipe 4000 (see BQ.5).
Page 38 Lotus Service Notes Section BQ Windscreen frame bonding (sills not shown) Windscreen frame Windsceen frame buttress Dash bafﬂe panel Bonding path b281a Page 15 sn_bq_cyclone.indd 15 03/03/2006 10:53:42...
Page 39 Lotus Service Notes Section BQ BQ.9 - SILL PANELS The sill panels incorporate the ‘A’ and ‘B’ posts, and are bonded to the chassis, windscreen frame and rear bulkhead panel. The sill bottom ﬂange, and rear end of the will top ﬂange are bonded into grooves in the chassis main side rails and it is necessary to cut the sills in the course of their removal: It is not practical to attempt to remove a sill panel intact for later reﬁtment.
Page 40 Lotus Service Notes Section BQ Remove excess sealant from all the bonding areas on the chassis and body panels. It is not necessary to remove all traces of old adhesive, but any remaining adhesive must be securely bonded and be cut with a scalpal blade to leave an even thickness of 1 - 2 mm.
Page 41 Lotus Service Notes Section BQ To replace the rear bulkhead: Remove the rear clamshell (see sub-section BR.6). Remove both seats, and the bulkhead interior trim panel. Remove from the inside of the bulkhead the microwave sensor and immobiliser module. Release all wiring harnesses from the bulkhead clips.
Page 42 Lotus Service Notes Section BQ visual areas. Secure in position with tape until the adhesive has cured. The heat/acoustic insulator panel is bonded to the bulkhead only at its centre section. Clean and prime the centre section on the bulkhead with Betaclean 3900 and Betaprime 5404, and apply Betaseal 1701. Press the insulator panel into position and ensure sufﬁcient compression of adhesive.
Page 43 Lotus Service Notes Section BR BODY FITTINGS SECTION BR Sub-Section Page Removable Roof BR.1 Rear Window Shroud (Elise only) BR.2 Front Body Access Panels BR.3 Engine Cover Lid BR.4 Door Hinge Cover Panel BR.5 Front Clamshell BR.6 Rear Clamshell BR.7 Door Mirrors BR.8...
Page 44 The Elise or Exige should not be subjected to an automatic car wash. Such machines can induce water leaks caused by high pressure water jets which are not representative of conditions encountered during normal use.
Page 45 Lotus Service Notes Section BR Roll out the left hand side of the roof, and engage the fixed spigot pin on the front and rear end of the rail, into the uppermost slot in the latch blocks at the front and rear of the roof aperture.
Page 46 Lotus Service Notes Section BR Roof Cable - Rear: The roof rear cable tension should be sufficient only to maintain stability of the roof canopy shape. Side Rail Front Latch Plates: The latch plates on the windscreen header rail are secured using a two part adhesive.
Page 47 Lotus Service Notes Section BR Using the special tool provided, install the windscreen header cover panel by locating first with the central screw, and then by the outer screws before tightening in the same order. Check that the roof is secure by pulling up- wards on each corner in turn.
Page 48 Lotus Service Notes Section BR BR.2 - REAR WINDOW SHROUD (Elise only) The rear window shroud is a body colour composite panel which covers the seat belt mounting frame/roof hoop, and forms a capping for the rear of the cockpit. The panel is secured by two brackets on its front edge which are fixed each side by a single M6 screw to the top of the rear bulkhead panel and which are accessible from within the cabin.
Page 49 WARNING: Ensure the access panels are refitted and properly secured before driving. Exige The access panels on the Exige model are shorter front to back than those of the Elise, and are retained by three socket head screws, the outermost of which features an adjustable plinth to allow panel height adjust- ment.
Page 50 Lotus Service Notes Section BR Theaded insert in engine lid Engine lid hinge Studplate clamping hinge & clamshell to bulkhead b318 Nut inside cabin Exige On Exige models, the double skin, moulded composite tailgate panel, mates with an air intake duct in the clamshell and roof panel to admit cooling air into the engine bay, and also features seven steel mesh grilles to allow for the exhaustion of hot air.
Page 51 Lotus Service Notes Section BR BR.5 - DOOR HINGE COVER PANEL A separate glass fibre composite body panel is used to fill the area beween the door and wheelarch, and uses threaded fasteners to attach to the rear of the clamshell, top of the sill and bottom inboard edge of the sill panel.
Page 52 Remove the fixing at each side securing the clamshell to the bottom of the windscreen frame. Elise: Remove the two nuts securing the clamshell spine bracket to the wiper motor bracket extension. Exige: Remove the two nuts and bolts securing the clamshell spine to the wiper motor extension bracket, and the two screws each side securing the clamshell channel to the radiator air deflector panel.
Page 53 'B' post above the engine bay air intake. Elise: From inside the cabin, release the fixings securing the engine lid hinges to the rear bulkhead, and withdraw the engine lid complete with hinges.
Page 54 Lotus Service Notes Section BR Release the six (USA market) or eight (other cars) screws securing the fuel filler neck to the clamshell. Withdraw the filler neck from the clamshell aperture, noting the earth braid secured to the roof hoop backstay.
Page 55 Lotus Service Notes Section BR Replacement of mirror glass Mirror mounting plinth The mirror glass is contained in a plastic surround which is clipped into the housing in order to provide for convenient and inexpen- sive replacement. To remove a glass, pull...
Page 56 Lotus Service Notes Section BR Exterior lock/finger Window rear guide Shell to beam grip bracket channel bracket front lower bracket 6mm holes 6mm holes b347 Prepare the bonding surface of the door panel using coarse emery cloth and clean with Betaclean 3900 (A100B6008V).
Page 57 Lotus Service Notes Section BR Door shell to Tapping plate beam fixing Shim plate Chassis outrigger Dirt shield Door beam (hinge rotor) Door restraint spring plate Plastic shoe Hinge bracket b243b (stator) Door beam pivot bearings The door beam hinge uses two maintenance free ’top hat’ section synthetic bearings, pressed into the hinge stator bracket.
Page 58 Lotus Service Notes Section BR Rubber bung Rotor bush Plastic bearing Door beam/ hinge rotor Stator bracket Cap head screw Hinge bracket fixings b244 BR.10 - DOOR SHELL ASSEMBLY The door shell is mounted on the door beam via three screws through a flange at the front end of the beam, and by the door latch mounting bracket at the rear end.
Page 59 Lotus Service Notes Section BR Beam to extension Door beam Captive Door beam bracket fixing extension fixing flange bracket Door beam Door shell to extension bracket fixing Door shell to beam fixing b245a When refitting the door, take care not to scratch the glass if this is contained in the door. Insert the two rear bolts securing the beam to the latch bracket, but do not tighten until the three fixings securing the front of the shell to the beam flange have been fitted and tightened.
Page 60 Lotus Service Notes Section BR Door glass lift channel Nylon guide block Door glass Guide rail Scissor Door Steel guide tilt top fixing linkage glass rail Adjuster Handle pinion screw Reaction Toothed sector channel Threaded block fixed Door to rail...
Page 61 Lotus Service Notes Section BR To adjust the alignment of the top edge of the glass, it is necessary to adjust the height of the reaction channel. Remove the window winder handle and door trim panel, slacken the reaction channel fixings, and move the channel up or down as required.
Page 62 Lotus Service Notes Section BR Door glass slider block Winder mechanism Lift channel Door glass stud plate b321 Reaction Scissor arm Winder channel pivot fixing mechanism fixing Adjust the glass upstop postion, top edge alignment and inward tilt as detailed above.
Page 63 Lotus Service Notes Section BR BR.12 - ELECTRIC WINDOWS (Parts List 11.02) On cars so equipped, switches for the electric windows are mounted in the front of the door trim panels, and are operative only with the ignition switched on. To help locate the switches in the dark, an illuminated dot is provided in the ‘down’...
Page 64 Lotus Service Notes Section BR Replacement of Window Lift Mechanism The window lift mechanism comprises the motor, drive cable and guide channel assembly as a complete unit. To remove the mechanism: If possible, raise the window fully for optimum access.
Page 65 Lotus Service Notes Section BR Note that the door glass is common to manually operated windows, with slider blocks bonded to the front and rear edges, and a studplate channel bonded to the lower edge. For electric window operation, an adaptor studplate is used to provide two studs for the window lift bracket.
Page 66 Lotus Service Notes Section BR Continue to remove the backing strip and stick the weatherstrip along the seal path down the 'B' post and along the bottom of the door aperture. Cut the seal to mate with the end of the front weatherstrip. Repeat for the opposite side, and then remove the top section backing strip and secure the seal along the roof shroud flange.
Page 67 Lotus Service Notes Section BR The door latch mechanism is fitted inside the rear face of the door, which is reinforced by a steel plate bonded to the glass fibre composite door shell. The latch engages with a striker pin which passes through the composite sill/'B' post moulding, into a captive nut on the roll over bar.
Page 68 Lotus Service Notes Section BR Latch Mechanism Remove the window winder handle and door trim panel. Unclip the control rod from the interior release handle, and unhook from the latch mechanism. Unclip and disconnect the short link rod between the relay lever and the latch mechanism.
Page 69 Lotus Service Notes Section BR BR.15 - CENTRAL DOOR LOCKING (Parts List 10.17) On cars so equipped, the central door locking (CDL) operates on the driver’s and passenger’s doors in conjunction with the Cobra 8185/8186 security alarm system. For full details of the alarm system, see sub- section MP.1.
Page 70 Lotus Service Notes Section BR BR.16 - INSTRUMENT BINNACLE & DASH PANEL (Parts List 14.10, 14.05, 14.05b) The dash panel comprises interlinking alloy extrusions which join the chassis scuttle beam to the base of the windscreen pillars, and also provide a mounting for the fascia top trip panel. The lowermost extrusion, which incorporates a curved shelf, is keyed into a slot in the scuttle beam and is secured by rivets at each end to the beam.
Page 71 Lotus Service Notes Section BR Release the two fixings securing the binnacle mounting brackets to the column, and withdraw the instru- ment pack and cowl. Unplug the harness connector. Instrument cowl Instrument pack Binnacle mounting bracket Mounting bracket fixing screw...
Page 72 Lotus Service Notes Section BR Moulded plastic Non-Airbag Type pl1405mt capping panel Capping panel fixing Fascia top panel Dash fixing to screen frame Column shroud Fascia to dash fixing Fascia top FLV/climate recess finisher control housing Dash lower extrusion Keyhole slot...
Page 73 Lotus Service Notes Section BR Airbag Type Instrument pack mounting bracket Column shroud support leg Fascia top panel Column shroud Dash fixings to screen frame FLV/audio housing Climate control Airbag housing door Airbag shute Dash upper extrusion Dash lower extrusion...
Page 74 Turn off the ignition. Before disconnecting the battery, use the Lotus Scan tool to read any stored trouble codes. 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 75 Lotus Service Notes Section BR BR.17 - WINDSCREEN (Parts List 11.01) The laminated windscreen, together with self coloured synthetic finisher moulded around the top and side edges, is bonded to the composite windscreen mounting frame using Betaseal flexible polyurethane adhesive.
Page 76 Lotus Service Notes Section BR After cutting out the screen, remove old adhesive from the windscreen frame sufficiently to leave a consistent and flat surface for the new bond. Clean the whole of the inside surface of the windscreen with a 50% solution of water and isopropanol.
Page 77 Lotus Service Notes Section BR 12. Cut three 4mm spacer blocks from the material supplied in the Betaseal kit, or from rubber or plastic material, and position in the inside edge of the adhesive bead running along the bottom of the class.
Page 78 Lotus Service Notes Section BR Spillage of material Any spillage of Betaseal onto unprimed glass can be readily peeled off after it has cured. Any spillage onto the bldy can be removed with either Wipe Cleaner No.4, or white spirit.
Page 79 Lotus Service Notes Section CI FRONT SUSPENSION SECTION CI Sub-Section Page General Description CI.1 Geometry & Adjustments CI.2 Anti-Roll Bar CI.3 Suspension Disassembly/Assembly CI.4 Front Wheel Bearings CI.5 For Super Sport Suspension, see DH.6 Page 1...
Page 80 Lotus Service Notes Section CI GENERAL LAYOUT Spring/damper unit Top wishbone Steering tie rod Upper swivel joint Track rod Steering Anti-roll bar mounting Anti-roll bar Bottom wishbone Hub carrier Wheel hub Lower steering swivel joint c34b Page 2...
Page 81 0.5 mm toe-out to 0.7 mm toe-in overall (0.07° toe-out to 0.10° toe-in overall) Steering axis inclination 12° nominal Sport Elise, Exige Mid-laden ride height (reference height for geometry check); - all except USA prior VIN 3013 - front 130 mm below front end of chassis siderail...
Page 82 Lotus Service Notes Section CI 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 83 Lotus Service Notes Section CI 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...
Page 84 Lotus Service Notes Section CI 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 85 Clamp bracket On Elise and Exige models built with 'Super Sport' suspension prior to August '06, a stiffer adjustable bar is used with 5 holes in each end to allow some adjustment of roll stiffness to be made. Standard setting is centre hole.
Page 86 Elise and Exige models built with 'Super Sport' suspension from August '06, use a yellow painted, standard rate, 5-hole adjustable bar, sharing the chassis mounting higher position of the standard bar but using hard plastic bushes housed in alloy clamps.
Page 87 - Standard Elise: Use centre of 3 grooves for mid-laden ride height of 130mm. - USA Elise: Use lower of 3 grooves for mid-laden ride height of 135mm. - Elise with sports suspension package and non-USA Exige: Use the upper of 2 grooves for mid-laden ride height of 130mm.
Page 88 Lotus Service Notes Section CI Reassembly Re-assemble the suspension in reverse order to disassembly with the following notes: Take care to assemble each pivot bolt with the correct washers/snubbers/spacers as shown in the dia- grams. Smear the shank of each pivot bolt with PBC grease, but do not allow contamination of the threads.
Page 89 Lotus Service Notes Section CI CI.5 - FRONT WHEEL BEARINGS The sealed front wheel bearings are contained in a steel housing secured to the hub carrier with three 'Torx' bolts. The double row, angular contact, ball bearing is retained in the outer housing and also onto the hub spigot by a shoulder and a peening operation, and is inseparable for service.
Page 90 Lotus Service Notes Section DH REAR SUSPENSION SECTION DH Sub-Section Page General Description DH.1 Geometry & Adjustments DH.2 Suspension Disassembly/Assembly DH.3 Rear Wheel Bearings DH.4 Track Use Chassis Rear Brace Kit DH.5 Super Sports Suspension Package DH.6 Page 1...
Page 91 Lotus Service Notes Section DH Rear Suspension Layout Damper top mount Upper ball joint Damper Hub carrier Top wishbone Rear subframe Rear subframe Lower wishbone Driveshaft Toe control link Wheel hub Road spring Lower ball joint d20b Page 2...
Page 92 1.2 to 1.8 mm toe-in each side (0.16° to 0.24° toe-in each side) Max. difference side/side: 0.3 mm (0.04°) Roadsport Elise, Exige (for Super Sport suspension see sub-section DH.6) Mid laden ride height (reference height for geometry check); - front...
Page 93 Lotus Service Notes Section DH 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 94 Lotus Service Notes Section DH 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 95 Lotus Service Notes Section DH DH.3 - SUSPENSION DISASSEMBLY/ASSEMBLY The suspension may be disassembled without the use of any special tools other than a 'Torx' socket for the hub bearing carrier bolts, a spring compressor required only if the spring is to be removed from the damper unit, and a ball joint splitter.
Page 96 - Standard Elise & USA from VIN 3013: Use centre of 3 grooves for mid-laden ride height of 130mm. - USA Elise prior VIN 3013: Use lower of 3 grooves for mid-laden ride height of 135mm.
Page 97 Note that on previous Elise models, there have been several variants of the toe-link inboard ball joint. The correct joint for 2005 model year onwards has a ball pin thread pitch of 1.25mm (vs. 1.5mm). The ﬂats on the ball pin should be aligned with the channel in the subframe hardened insert.
Page 98 Lotus Service Notes Section DH Do not operate the car without the exhaust silencer heatshielding correctly ﬁtted, and incorporating heat- shields for the toe-link inboard ball joints. Press the brake pedal to reposition the pads before driving the car. If the car suffers a suspension impact sufﬁcient to damage a wheel rim, careful attention should be paid to all related suspension components.
Page 99 Lotus Service Notes Section DH To Replace Hub Bearing Assembly With the wheel removed, apply the parking brake, remove the split pin from the nut retaining the driveshaft in the hub, and release the nut. Release the two ﬁxing bolts, and remove the brake caliper from the hub carrier. Support clear of the brake disc without straining the ﬂexible hose.
Page 100 For cars used on closed circuits, this arrangement provides an increased tolerance to abuse. It may be retroﬁtted on any Elise 111R/'04 Exige/USA Elise (i.e. Toyota power- train cars).
Page 101 Lotus Service Notes Section DH Tighten the turnbuckle locknuts to 45 Nm whilst holding the adjacent adaptor lug, and then tighten the engine steady mountings to 45 Nm. Adjust rear wheel alignment only at mid-laden ride height of 130mm to 1.5mm toe-in each side (±...
Page 102 Lotus Service Notes Section DH Section B thro' steady mounting attachment (adjustable type crossbrace) Engine steady mounting Cross-brace welded bracket Chassis Cross-brace tube FRONT General view Cross-brace ﬁxing Adaptor lug to subframe Turnbuckle Cross-brace Page 13...
Page 103 Section DH DH.6 - SUPER SPORT SUSPENSION To provide customers for 6-speed Elise/Exige with a track optimised suspension choice, a 'Super Sport' suspension speciﬁcation was introduced in early 2006 as a factory build option package comprising: Bilstein dampers with thread adjustable spring platforms and 10 position combined damping adjustment.
Page 104 ﬂat washer A120W4199F (7/16 x 7/8) must be used between the head of the toe link pivot bolt and the crossbrace tube. Forged Wheels The lightweight forged wheels offer a saving of 14.4 kg/car on Elise and 20.4 kg/car for Exige, and feature a wider front rim width of 6.5J. Insets are unchanged. Yokohama A048 Tyres The Yokohama A048 tyres have been developed jointly by Lotus and Yokohama to suit the requirements of the performance driver, with special emphasis on track use.
Page 105 1.5 to 2.0 mm (0.20 to 0.27°) toe-in each side max.side/side 0.3 mm (0.04°) Super Sport Suspension Retroﬁt To retro-ﬁt Super Sport suspension to a Toyota powertrain Elise/Exige, the following parts and procedure may be used: Parts Required Part Number...
Page 106 Lotus Service Notes Section DH Procedure Anti-Roll Bar - stiffened rate adjustable Remove the anti-roll bar after ﬁrst drilling out the rivets securing the reinforcing brackets between the bottom of the crash structure and the chassis. The adjustable anti-roll bar is secured by two Nylon clamps, ﬁxed to the chassis via the front lower wish- bone inboard front pivot bolt, with a 'top hat' section steel spacer preventing the clamp from being crushed.
Page 107 Lotus Service Notes Section DH Modify Front Damper Bracket Remove all four spring/damper units and front wheelarch liners (refer Service Notes section CI). The upper eye of the alloy bodied Bilstein sport damper is larger than the standard steel eye and requires that the front suspension upper clevis bracket (bolted to the chassis), is modiﬁed in order to provide the...
Page 108 The chassis brace kit is fully described in Section DH.5. Forged Wheels The lightweight forged wheels offer a saving of 14.4 kg/car on Elise and 20.4 kg/car for Exige, and feature a wider front rim width of 6.5J. Insets are unchanged.
Page 109 SECTION EH Sub-Section Page General Description EH.1 Maintenance Operations EH.2 Engine Removal/Replacement EH.3 Special Tools EH.4 Engine Management Component Location EH.5 Elise S Supplement (1ZZ-FE) EH.6 See also Toyota engine repair manual B120T0327J and Toyota 2ZZ-GE engine supplement C120T0327J Page 1...
Page 110 Lotus Service Notes Section EH Engine Sections (2ZZ-GE) From LH side From front e226 Cylinder head section Exhaust side Intake side e227 Page 2...
Page 111 EH.1 - GENERAL DESCRIPTION The 1.8 litre, 16 valve four cylinder engine used in the Lotus 2005 model Elise is supplied by Toyota Mo- tor Corporation, and is designated '2ZZ-GE'. The engine number is stamped on the rear end of the cylinder block, exhaust side, and is followed by '2ZZ'.
Page 112 Lotus Service Notes Section EH e223 e222 e224 Page 4...
Page 113 Lotus Service Notes Section EH Note that compromises are involved in the programming of inlet cam timing, since advancing the valve opening point also advances the valve closing point, when the ideal might be to advance the opening and retard the closing points.
Page 114 Lotus Service Notes Section EH e225 Page 6...
Page 115 Service replacement shells will also be marked on the back with the size code. Knock Sensor The knock sensor used for Lotus applications is an annular type ﬁtted over an M8 stud, with the retaining nut tightened to 20 Nm. EH.2 - MAINTENANCE OPERATIONS...
Page 116 ﬁlter wrench, and dispose of safely. Ensure that only a Lotus speciﬁed ﬁlter is ﬁtted, as parts with identical outward appearance can contain different internal features. Before ﬁtting a new ﬁlter, clean the mating face on the engine, and smear the new seal on the ﬁlter with clean oil.
Page 117 Lotus Service Notes Section EH removal. Start the engine and check for oil leaks. Re-check the security of the ﬁlter, further tightening by hand if necessary. Check the oil level (see above) when the engine is fully warm. Oil Coolers The foregoing oil change procedure does not disturb the oil quantity contained in the twin oil coolers and associated pipework, but is considered perfectly satisfactory for routine maintenance operations.
Page 118 Lotus Service Notes Section EH Air Cleaner Element The air ﬁlter should be inspected at intervals dependent on the operating conditions. When the vehicle is operated in a relatively clean environment, the element should be renewed at intervals speciﬁed in the Main- tenance Schedule, but where a dusty or smog laden atmosphere prevails, or other factors contribute to ﬁlter...
Page 119 Lotus Service Notes Section EH EH.3 - ENGINE REMOVAL/REPLACEMENT It is recommended to remove the rear clamshell prior to powertrain removal in order to improve access, and to reduce the possibility of paint damage. The engine may be removed from above, with or without the transmission.
Page 120 Lotus Service Notes Section EH Remove the engine bay undertray and diffuser, both rear road wheels and the rear clamshell (see sub- section BR.7). On a.c. cars, recover refrigerant and disconnect both a.c. hoses from the pipes at the rear of the RH sill.
Page 121 For coolant reﬁlling procedure, refer to section KH. For transmission details and gear cable adjustment, refer to section FJ. EH.4 - SPECIAL TOOLS The following engine special tools are available under Lotus part number: Engine Lift Bracket T000T1437S 2 off...
Page 122 Lotus Service Notes Section EH EH.5 - ENGINE MANAGEMENT COMPONENT LOCATION Key to engine management component location drawing Electronic Control Unit (ECU). Multi-function relay unit. Oil control valve for variable valve lift. Camshaft position sensor. Fuel injector. Knock sensor. Oil control valve for variable valve timing.
Page 123 EH.6 - ELISE S SUPPLEMENT The Elise S, introduced in May 2006 uses the Toyota '1ZZ-FE' engine instead of the '2ZZ-GE' ﬁtted in the Elise 111R. The two engines are similar in basic architecture, with the 2ZZ having been derived from the 1ZZ, and whilst the overhaul procedures are largely common, many of the principal components are different.
Page 124 Lotus Service Notes Section EMP ENGINE MANAGEMENT SECTION EMP Sub-Section Page Diagnostic Trouble Code List EMP.1 'Lotus Scan' Diagnostic Tool EMP.2 Engine Management Component Location EMP.3 Mechanical Throttle Setting Procedure EMP.4 2006 Model Year Electronic Throttle Control EMP.5 Diagnostic Trouble Code Supplement - '06 M.Y.
Page 125 Lotus Service Notes Section EMP EMP.1 - DIAGNOSTIC TROUBLE CODE LIST Fault description Page P0011 Camshaft Position - Timing Over-Advanced or System Performance P0012 Camshaft Position - Timing Over-Retarded P0076 Intake Valve Control Solenoid Circuit Low P0077 Intake Valve Control Solenoid Circuit High...
Page 126 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 Elise/Exige uses a Lotus ECU, the connections for which may be found in circuit diagrams in Section MP. Diagnostic Trouble Codes should be read using a Lotus Scan tool T000T1418F.
Page 127 Lotus Service Notes Section EMP Camshaft Timing Control (VVT) P0011 P0012 P0076 P0077 P0011 Camshaft Position – Timing Over-Advanced or System Performance P0012 Camshaft Position – Timing Over-Retarded P0076 Intake Valve Control Solenoid Circuit Low P0077 Intake Valve Control Solenoid Circuit High Description The Variable Valve Timing system (VVT) on the intake camshaft can vary the timing by approximately 25°.
Page 128 Lotus Service Notes Section EMP Intake Air Flow P0101 P0102 P0103 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 129 Lotus Service Notes Section EMP P0103 Enable Criteria: Engine running Disable Criteria: None Potential failure modes: • MAF sensor battery voltage open circuit (MAF value (g/sec) = 0.0) • MAF sensor signal open circuit or short to ground (MAF value (g/sec) = 0.0) •...
Page 130 Lotus Service Notes Section EMP Barometric Pressure P0106 P0107 P0108 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 131 Lotus Service Notes Section EMP Intake Air Temperature P0111 P0112 P0113 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 measure both Mass Air Flow (MAF) and Intake Air Temperature (IAT) is incorpo- rated into the airbox.
Page 132 Lotus Service Notes Section EMP P0113 Enable Criteria: Engine running Disable Criteria: None Potential failure modes: • Signal open circuit (IAT > 140°C (284°F) > 4.932 V) • Sensor failure Notes: • The MIL will be illuminated if the fault is present for 2 consecutive trips •...
Page 133 Lotus Service Notes Section EMP Engine Coolant Temperature P0116 P0117 P0118 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 134 Lotus Service Notes Section EMP Notes: • The MIL will be illuminated if the fault is present for 2 consecutive trips • Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J) page DI-39 to DI-45 Page 11 sn_emp_cyclone.indd 11...
Page 135 Lotus Service Notes Section EMP Throttle Position P0121 P0122 P0123 P0121 Throttle Position Sensor 'A' Circuit Range/Performance P0122 Throttle Position Sensor 'A' Circuit Low P0123 Throttle Position Sensor 'A' Circuit High Description The Throttle Position Sensor (TPS) is a potentiometer device, which is connected to a 5V reference source, a ground and an input signal to the ECU.
Page 136 Lotus Service Notes Section EMP P0122 Enable Criteria: None Disable Criteria: P0016 – Crankshaft/Camshaft position correlation error Potential failure modes: • Signal short circuit (< 0.283 V) • Reference voltage open circuit • Reference voltage short to ground • Sensor failure...
Page 137 Lotus Service Notes Section EMP Coolant Thermostat P0128 P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) Description The thermostat diagnostic is enabled after each cold engine start, and monitors the rate of temperature rise during warm up relative to the measured engine air ﬂow.
Page 138 Lotus Service Notes Section EMP O2 Sensor (Pre Catalyst) P0131 P0132 P0133 P0134 P0135 P0131 O2 Sensor 1 Circuit Low Voltage P0132 O2 Sensor 1 Circuit High Voltage P0133 O2 Sensor 1 Circuit Slow Response P0134 O2 Sensor 1 Circuit No Activity Detected...
Page 139 Lotus Service Notes Section EMP Potential failure modes: • High fuel pressure (Rich mixture) • Leaking or shorted injector • Purge valve fault • Oxygen sensor contamination • Engine oil contamination • Sensor wire P0133 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.
Page 140 Lotus Service Notes Section EMP Potential failure modes: Sensor connector and wiring should be checked for corrosion and loose connections. Notes: • The MIL will be illuminated if the fault is present for 2 consecutive trips. • Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J)
Page 141 Lotus Service Notes Section EMP O2 Sensor (Post Catalyst) P0137 P0138 P0139 P0140 P0141 P0137 O2 Sensor Circuit Low Voltage P0138 O2 Sensor Circuit High Voltage P0139 O2 Sensor Circuit Slow Response P0140 O2 Sensor Circuit No Activity Detected P0141...
Page 142 Lotus Service Notes Section EMP Potential failure modes: • Check and rectify any front sensor fault code, as they may be causing the fault code to be set • Catalyst P0139 Set when the sensor fails to reach 650mV after 1.9 seconds of P.E or when the sensor fails to drop below 150mV after 5 seconds of DFCO ('06 M.Y.;...
Page 143 Lotus Service Notes Section EMP Fuel Control System Too Lean Or Rich P0171 P0172 P0171 System Too Lean P0172 System Too Rich 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 144 Lotus Service Notes Section EMP Fuel Injection System P0201 P0202 P0203 P0204 P0201 Injector Circuit/Open – Cylinder 1 P0202 Injector Circuit/Open – Cylinder 2 P0203 Injector Circuit/Open – Cylinder 3 P0204 Injector Circuit/Open – Cylinder 4 Description The ECU has four injector driver circuits, each of which controls an injector. When the engine is running the ECU continuously monitors the injector circuit feedback signals.
Page 145 Lotus Service Notes Section EMP Misﬁre P0300 P0301 P0302 P0303 P0304 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 Description A misﬁring cylinder can be detected by analysing crank speed variation. As a result of a combustion event there will be a net acceleration of the crankshaft.
Page 146 Lotus Service Notes Section EMP Notes: • The MIL will be illuminated if the fault is present for 2 consecutive trips. • Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J) pages DI-73 to DI-78 Page 23 sn_emp_cyclone.indd 23...
Page 147 Lotus Service Notes Section EMP Knock Control System P0324 P0327 P0328 P0324 Knock Control System Error P0327 Knock Sensor 1 Circuit Low P0328 Knock Sensor 1 Circuit High Description The knock sensor contains a piezoelectric element which generates a voltage when it becomes deformed. The piezoelectric element sends the signal to the ECU, when the cylinder block vibrates due to engine knocking.
Page 148 Lotus Service Notes Section EMP Engine Speed / Position Sensors P0335 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 149 Lotus Service Notes Section EMP Engine Speed / Position Sensors P0340 P0340 Camshaft Position Sensor “A” Circuit Description The camshaft position input to the ECU is used to determine engine phase, enable sequential fuel injection control and to determine camshaft position for the VVT system. The inlet camshaft has three ‘teeth’ spaced 90°...
Page 150 Lotus Service Notes Section EMP Ignition System P0351 P0352 P0353 P0354 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 Description A Direct Ignition System (DIS) is used on the engine. The DIS improves the ignition accuracy, reduces high- voltage loss, and enhances the reliability of the ignition system.
Page 151 Lotus Service Notes Section EMP Catalyst System Efﬁciency P0420 P0420 Catalyst System Efﬁciency Below Threshold 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. If the catalyst is functioning normally the front oxygen sensor will be switching between rich and lean whilst the rear oxygen sensor should also be switching between rich and lean but more slowly.
Page 152 Lotus Service Notes Section EMP Evaporative Emission Control – Leak Detection System P0441 P0442 P0455 P0456 P0441 Evaporative Emission System Incorrect Purge Flow P0442 Evaporative Emission System Leak Detected (small leak) P0455 Evaporative Emission System Leak Detected (large leak) P0456...
Page 153 Lotus Service Notes Section EMP Purge valve stuck open A purge valve that is unable to seal correctly will result in a tank evacuation during the sealing phase of the leak check sequence. In this phase, a pressure rise would normally be expected but when the purge valve is not sealing this causes depression in the tank.
Page 154 Lotus Service Notes Section EMP Evaporative Emission Control – Purge, Open / Closed Circuit P0444 P0445 P0446 P0447 P0448 P0451 P0452 P0453 P0444 Evaporative Emission System Purge Control Valve Circuit Open P0445 Evaporative Emission System Purge Control Valve Circuit Closed...
Page 155 Lotus Service Notes Section EMP Fuel Level Sensor P0461 P0462 P0463 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 156 Lotus Service Notes Section EMP Engine Cooling Fan Control P0480 P0481 P0480 Fan 1 Control Circuit P0481 Fan 2 Control Circuit Component connections Sensor Connector Description ECU Pin ECU Connector 2 (ACCM 2*) Relay #1 67 (J2) 28 Way (Left) '06 M.Y.
Page 157 Lotus Service Notes Section EMP Vehicle Speed Sensor P0500 P0500 Vehicle Speed Sensor “A” Description The ECU uses the left rear wheel speed sensor to determine vehicle speed. This output to the ECU is via the ABS module. Sensor connections...
Page 158 Lotus Service Notes Section EMP Idle Speed Control P0506 P0507 P0508 P0509 P0506 Idle Air Control System RPM Lower Than Expected P0507 Idle Air Control System RPM Higher Than Expected P0508 Idle Air Control System Circuit Low (prior '06 M.Y.) P0509 Idle Air Control System Circuit High (prior '06 M.Y.)
Page 159 Lotus Service Notes Section EMP Battery Voltage P0562 P0563 P0562 System Voltage Low P0563 System Voltage High Monitor: Continuous Enable Criteria: • Engine running • P0562 – Voltage Too Low < 10V • P0563 – Voltage Too High > 16V...
Page 160 Lotus Service Notes Section EMP ECU Integrity P0601 P0606 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 power down. P0606 checks the watchdog timer after a deﬁned period to see if it has reset.
Page 161 Lotus Service Notes Section EMP Fuel Pump P0627 P0627 Fuel Pump Control Circuit /Open Description The fuel system is of the non-return type. The pump is incorporated into the fuel tank module which also con- tains the level sensor, regulator and vapour pressure sensor.
Page 162 Lotus Service Notes Section EMP Air Conditioning System P0646 P0647 P0646 A/C Clutch Relay Control Circuit Low P0647 A/C Clutch Relay Control Circuit High Component connections Connector Description ECU Pin ECU Connector 5 (ACCM 2*) AC Clutch Relay 53 (J1) 28 Way (Left) '06 M.Y.
Page 163 Lotus Service Notes Section EMP Misﬁre P1301 P1302 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. If the misﬁre percentage is high enough and there is a possibility that the catalyst may be damaged then code P1302 will be set.
Page 164 Lotus Service Notes Section EMP Coolant Recirculation Pump P2602 P2603 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.
Page 165 Lotus Service Notes Section EMP Camshaft Lift Control (VVL) P2646 P2647 P2648 P2649 P2646 A Rocker Arm Actuator System Performance or Stuck Off P2647 A Rocker Arm Actuator System Stuck On P2648 A Rocker Arm Actuator Control Circuit Low P2649...
Page 166 Data Link Connector (DLC), located at the front of the passenger footwell. Note that this tool may also be used on previous Elise models (excluding Exige, 340R and 160 models). Amongst the operations available using the ‘Lotus Scan’ tool are:...
Page 167 Lotus Service Notes Section EMP 2. Downloading software from P.C. With early type adaptor lead Connect to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c With later type adaptor Connect to COM port on PC...
Page 168 Lotus Service Notes Section EMP EMP.3 - ENGINE MANAGEMENT COMPONENT LOCATION Key to engine management component location drawing Electronic Control Unit (ECU). Multi-function relay unit. Oil control valve for variable valve lift. Camshaft position sensor. Fuel injector. Knock sensor. Oil control valve for variable valve timing.
Page 169 Lotus Service Notes Section EMP EMP.4 - MECHANICAL THROTTLE SETTING PROCEDURE (Prior '06 M.Y.) To avoid throttle cable strain, and ensure correct idle control and pedal operation, the following adjustments must be maintained. If the pedal downstop is incorrectly set, overloading of the throttle body cable quadrant can occur, resulting in quadrant distortion, closed throttle position error and engine stalling: Check the throttle body cable quadrant for distortion and mis-alignment.
Page 170 2006 model year cars with ETC have the VIN included in the ECU memory, without which the MIL will be illuminated, and a fault code stored. The Lotus Scan tool requires an updated operating programme which includes VIN download facility and is available on CD under part number T000T1466/2. This programme must be downloaded on to a PC before being transferred to the Scan tool.
Page 171 Lotus Service Notes Section EMP EMP.6 - DIAGNOSTIC CODE SUPPLEMENT - '06 M.Y. New fault codes for '06 M.Y. cars with electronic throttle control are as follows: Fault Description Page P0016 Crankshaft Position – Camshaft Position Correlation Error (P0121/P0122/P0123 Throttle Position Sensor 'A' - see page 12)
Page 172 Lotus Service Notes Section EMP Crankshaft Position–Camshaft Position Correlation Error P0016 Description The crankshaft position sensor is used to identify engine position and speed via a pole wheel mounted on the front end of the crankshaft. The camshaft position sensor is used to determine camshaft position from a three vane reluctor on the rear end of the inlet camshaft.
Page 173 VIN Not Programmed or Incompatible – ECU/PCM P0630 Description The ECM programming includes the Vehicle Identiﬁcation Number (VIN). This operation is performed using the Lotus Scan tool. Enable Criteria: # Engine running (for up to 4 seconds) Disable Criteria: None...
Page 174 Lotus Service Notes Section EMP Throttle Actuator Control Motor Circuit/Open P2100 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 Throttle Actuator Control Motor Circuit/Low...
Page 175 Lotus Service Notes Section EMP Throttle Actuator Control System – Forced Engine Shutdown P2105 Description If a problem is detected which could result in engine speed runaway, or if sufﬁcient control of engine speed is lost, the ECU switches off the fuel injectors in order to stop the engine.
Page 176 Lotus Service Notes Section EMP Throttle Actuator Control Module Performance P2108 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 Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU.
Page 177 Lotus Service Notes Section EMP Pedal Position Sensor 'E' Circuit Low P2127 Description Two potentiometers are built into the throttle pedal unit in order to provide a throttle demand signal to the ECU. Note that the potentiometers operate on 5 volts.
Page 178 Lotus Service Notes Section EMP Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation P2138 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 179 Lotus Service Notes Section FJ TRANSMISSION SECTION FJ Sub-Section Page Introduction FJ.1 Gearchange Mechanism FJ.2 Lubrication FJ.3 Driveshafts FJ.4 Transmission Replacement FJ.5 Transmission Overhaul & Special Tools FJ.6 See also Toyota transmission repair manual D120T0327J Page 1 sn_fj_cyclone.indd 1 03/07/2006 15:06:28...
Page 180 FJ.1 - INTRODUCTION The 5-speed Elise S transmission, and the 6-speed variant used on all other models, are both 'end on' type, mounted on the left hand end of the engine unit, and comprise the clutch housing, gearbox, ﬁnal drive gears, and differential.
Page 181 Lotus Service Notes Section FJ The clutch housing bolts to the back of the engine block and provides a dry chamber for the clutch mecha- nism, and roller bearings for the gearbox input and output shafts. The taper roller bearing for the differential RH output shaft is also accommodated.
Page 182 ﬁnal drive output gear, and supported in two taper roller bearings. Optional on some models, in conjunction with electronic Lotus Traction Control (LTC), is a Torsen type limited slip differential (LSD) in an otherwise un- changed transmission housing (Character 3 of 7 digit code on bar code label: 'O' = open; 'L' = LSD). The LSD uses worm wheels to interconnect the two output shafts and uses the poor torque reversal efﬁciency of this...
Page 183 Lotus Service Notes Section FJ 5-Speed The gear lever is spring biased towards the 3rd/4th gear plane, and must be moved against light spring pressure to the left before selecting ﬁrst or second gear, or against similar pressure to the right before selecting 5th.
Page 184: Transmission
Lotus Service Notes Section FJ The front end of both inner cables are equipped with socket joints which may be clipped on and off the ball pins provided on the gearchange mechanism. The outer cables are retained by a forked plastic block bolted into the gearlever/handbrake mounting frame.
Page 185 Lotus Service Notes Section FJ Page 7...
Page 186 Lotus Service Notes Section FJ Gearlever Mounting Frame The gear lever/parking brake lever mounting frame is common to right and left hand drive cars, but is mounted offset towards the passenger side of the car in order to allow sufﬁcient room for fore/aft adjustment of the driver's seat.
Page 187 Lotus Service Notes Section FJ Bellcrank lever plastic socket 'G' clamp Use suitable bolt to push back socket Special tool A120U0054S (Some components omitted for clarity) f135 Push the plastic socket in the bellcrank lever fully into the guide tool to facilitate installation of the gear lever.
Page 188 Lotus Service Notes Section FJ 11. Fit the new lift tube adaptor onto the gear lever and ensure it is free to slide up and down. Hook in the reverse selector cable and secure to the gear lever abutment. Temporarily ﬁt the new lift tube onto the adaptor and screw on the new gear knob.
Page 189 Lotus Service Notes Section FJ FJ.4 - DRIVE SHAFTS Each of the two driveshaft assemblies comprises a steel shaft with a constant velocity joint at each end, and is used to transmit the drive from each differential output gear to the rear wheel hub. The two driveshaft...
Page 190 Lotus Service Notes Section FJ Clicking noises, torque reversal 'clonks', or shudder and vibration when accelerating are all possible symp- toms of worn C.V. joints. It should not be possible to discern any free play in a joint, but care must be taken not to confuse this with transmission backlash, which may be considerable.
Page 191 Lotus Service Notes Section FJ Driveshaft C.V. Joint and/or Gaiter Replacement The outboard C.V. joint is supplied complete with main driveshaft to which it is ﬁxed by a spline with a small helix angle to eliminate any potential backlash. Separation of the shaft from the joint should not be attempted.
Page 192 Lotus Service Notes Section FJ 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. Press a new bearing into the housing, and retain with a new circlip. Then use...
Page 193 FJ.6 - TRANSMISSION OVERHAUL The overhauling of the Toyota supplied type C64 transmission, is detailed in separate publication D120T0327J which may also be used for guidance with the C56. Special tools are available through Lotus under the following part numbers:...
Page 194 If the input shaft oil seal is to be replaced, the bearing should also be renewed since this is likely to be damaged during oil seal removal. The reverse select compression spring shown in the Toyota Repair Manual is not ﬁtted in the Lotus ap- plication.
Page 195 Lotus Service Notes Section GH WHEELS & TYRES SECTION GH Sub-Section Page General Description GH.1 Wheels GH.2 Tyres GH.3 Winter Tyres & Snow Chains GH.4 Punctured Tyre Emergency Inﬂator GH.5 Tyre Pressure Monitoring System (TPMS) - '08 onwards USA only GH.6...
Page 196 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 197 Silver painted or natural anodised ﬁnish. Front wheel max. load rating 255 kg Size - front - Elise std 5.5J x 16 (cast) - Elise option 6.0J x 16 (forged + AD07 or A048) - Elise option 6.5J x 16 (forged + A048) - Exige 6.5J x 16...
Page 198 Typical security code; FEOR17025 GH.3 - TYRES Elise 111R prior '06 M.Y.: Lotus engineers worked with the tyre manufacturer Bridgestone, to produce a version of the ‘Potenza RE040’ tyre speciﬁcally for the Lotus Elise 'Mk.2' including Elise 111R, to optimise performance on both road and track.
Page 199 The tyres are NOT suitable for studding. Snow Chains In extreme conditions, Lotus approves the ﬁtment of Pewag Neon X3 - NX 373 snow chains, used only in conjunction with winter tyres (see above) and ﬁtted on only the rear wheels. Close attention should be paid to the ﬁtting and tensioning instructions supplied with the chains, and the chains should be removed as soon...
Page 200 In order fully to exploit the beneﬁts of light weight, and to maximise stowage space, no TYRE INFLATOR AEROSOL spare wheel is included in the Elise speciﬁca- tion, but a temporary puncture repair facility is provided in the form of a tyre inﬂator aerosol.
Page 201 GH.6 - TYRE PRESSURE MONITORING SYSTEM (TPMS) - USA ONLY All USA Elise/Exige models from ‘08 model year onwards are ﬁtted with a tyre pressure monitoring system. 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.
Page 202 Lotus Service Notes Section HG STEERING SECTION HG Sub-Section Page General Description HG.1 Steering Wheel HG.2 Upper Column Assembly HG.3 Intermediate Column HG.4 Front Wheel Alignment & Rack Gaiters HG.5 Rack & Pinion Assembly Removal/Replacement HG.6 Adjustment of Rack Bar Thrust Pad HG.7...
Page 203 Track rod HG.1 - GENERAL DESCRIPTION The steering system of the Elise comprises a telescopically collapsible upper column assembly, connect- ing to a rigidly mounted rack and pinion assembly via a universally jointed intermediate shaft. The steering rack tie rods connect to rearward facing steering arms bolted to the forged steel front hub carriers, with geom- etry providing 30% Ackermann effect, and a toe-out on bump characteristic.
Page 204 Lotus Service Notes Section HG module is incorporated in the centre of the wheel, and uses a rotary coil unit to maintain cable continuity to the airbag and horn buttons. To Remove Steering Wheel (non airbag type) Pull off the centre trim pad with horn...
Page 205 Lotus Service Notes Section HG To Remove Steering Wheel (airbag type) WARNING: The driver's airbag is housed in the hub of the steering wheel. Precautions need to be taken for personal safety when working with airbags and associated componentry. Do not attempt to remove the airbag or steering wheel without first referring to section WD.
Page 206 Lotus Service Notes Section HG Turn the steering to each full lock in turn and set the steering wheel on the column splines such that its orientation in one full lock position is the nearest possible mirror image of its position at the opposite full lock.
Page 207 Lotus Service Notes Section HG The upper steering column assembly comprises an inner column which connects the steering wheel to the intermediate shaft, and a tubular steel outer column which, with its alloy upper bearing housing, supports the inner column and carries the column lever switches for lighting and wiper control, and also the ignition switch/steering lock.
Page 208 Lotus Service Notes Section HG Outer Inner column column assembly lower end 80 ± 1 mm 58 ± 1 mm Inner Column Upper With the steering wheel removed, measure the length of the exposed part of the upper column as shown: Specification = 76 ±...
Page 209 Lotus Service Notes Section HG To Remove Upper Steering Column Assembly WARNING: On cars so equipped, the driver's airbag is housed in the hub of the steering wheel. Precautions need to be taken for personal safety when working with airbags and associated componentry.
Page 210 Lotus Service Notes Section HG Instrument pack Instrument cowl Instrument mounting bracket fixings (4 off) Upper column clamp fixings b343 Refit the column in reverse order to removal with the following notes: The groove for the pinch bolt allows assembly of the universal joint to the intermediate column in only one orientation.
Page 211 Lotus Service Notes Section HG Provision is made for the adjustment of front wheel alignment at the joint between the steering rack track (tie) rods, and the outer ball joints ('track rod ends'). The required ride height and alignment specification is detailed in sub-section CI.2.
Page 212 Lotus Service Notes Section HG Steering rack Steel reinforcement channel (bonded) assembly Height setting plate M10 fixing bolt M8 fixing bolt Pop rivet Chassis crossmember To Remove/Replace Steering Assembly Remove the nut securing each track rod end to the steering arm, and use a ball joint splitter to separate the joint.
Page 213 Lotus Service Notes Section HG Fit the lower u/j pinch bolt, and tighten to 35 Nm. Fit the track rod ends into the steering arms, and tighten the nuts to 30 Nm. 10. Check and adjust the front wheel alignment as detailed in sub-section CI.2.
Page 214 Lotus Service Notes Section HG Exploded View Oil seal Circlip Ball bearing Pinion Thrust pad Locknut Coil spring Threaded plug Sectional View Pinion shaft Oil seal Circlip Thrust pad Ball bearing Locknut Rack bar Threaded plug Pinion Needle roller bearing...
Page 215 '08 M.Y. Upgrade Option JJ.8A Brake Master Cylinder JJ.9 Vacuum Servo JJ.10 Pedal Box JJ.11 ABS Theory of Operation JJ.12 ABS Electro-Hydraulic Unit JJ.13 Wheel Speed Sensors JJ.14 Data Link Connector (DLC) JJ.15 Special Tools JJ.16 'Lotus Scan' Checking Procedures JJ.17 Page 1...
Page 216 Lotus Service Notes Section JJ Page 2...
Page 217 Section JJ JJ.1 - GENERAL DESCRIPTION The Lotus Elise, when fitted with anti-lock brakes, comprises ventilated discs all round with AP Racing 2- piston fixed callipers on the front and Brembo single piston sliding callipers on the rear. A tandem master cylinder, with vacuum servo assistance, operates the callipers via a front/rear split hydraulic circuit with anti- lock control by a Kelsey-Hayes microprocessor based system.
Page 218 Lotus Service Notes Section JJ tyre conditions. However, a wheel that completely locks and stays locked for more than one or two seconds is not normal, and indicates that the vehicle should be serviced as soon as possible. The ABS cannot operate properly if the base brake system is faulty, and will also be affected by dragging brakes, faulty wheel bearings or other related faults.
Page 219 Connect the Lotus Scan tool and select ABS and follow the brake bleeding instructions. Whilst this automatic process is taking place (with all 4 calliper nipples open), gently cycle the brake pedal up and down whilst keeping the reservoir topped up, to move any air bubbles displaced from the ABS unit down the hydraulic lines.
Page 220 Lotus Service Notes Section JJ Before replacing the pads, inspect the calliper for any signs of fluid leakage from a piston seal or joint, and replace the calliper if any such signs are evident. Clean the pad recess in the calliper taking suitable precautions to protect from dust inhalation.
Page 221 Lotus Service Notes Section JJ Tools Required: Pad retaining pin Piston Retraction Tool T000T1242 Remove the rear road wheels. At each rear corner: using a suitable pin punch, knock the pad retaining pin out of the calliper towards the outside, tak-...
Page 222 Lotus Service Notes Section JJ Top surface of bridge including Bottom surface of bridge inner surface in contact with including inner surface pad backplate in contact with pad backplate j188 Slide the brake pads into the calliper. Position the pad anti-rattle spring in the calliper aperture, with the spring ends located in the recesses provided.
Page 223 Lotus Service Notes Section JJ JJ.6 - PARKING BRAKE MECHANISM Operation of the parking brake lever applies a pull to a short link cable which connects via a horseshoe compensator to the centre of a single cable linking the two rear callipers. At each calliper, the cable connects...
Page 224 Lotus Service Notes Section JJ After verifying this dimension, any slack in the rear cable may be adjusted out at the left hand outer cable abutment, which is integral with the pivot bracket for the front leg of the lower wishbone. Remove the engine bay undertray for access.
Page 225 Lotus Service Notes Section JJ Unscrew the gear lever knob. Release the fixing screw at either side of the gear lever shroud base. Remove the single screw retaining the rear bulkhead centre pocket, and then the two screws securing the rear shroud.
Page 226 Lotus Service Notes Section JJ JJ.8 - BRAKE CALLIPERS The front brake callipers are manufactured by A.P. Racing, and are to be dismantled or overhauled only by their factory at Wheeler Road, Seven Stars Industrial Estate, Coventry, CV3 4LB. Torque settings:...
Page 227 Lotus Service Notes Section JJ JJ.8A - '08 MODEL YEAR UPGRADE OPTION Introduced as an option for some '08 models, is an uprated front brake kit, comprising 4-piston front callipers, larger diameter front discs and steel braided hoses. Front Callipers: At each front corner, the A.P.
Page 228 Lotus Service Notes Section JJ JJ.9 - BRAKE MASTER CYLINDER The tandem brake master cylinder is mounted in the front compartment and is secured to the brake servo by two studs with M8 nuts. The cylinder uses two pistons to supply the independent front and rear brake circuits.
Page 229 Lotus Service Notes Section JJ JJ.10 - VACUUM SERVO UNIT The FTE brake vacuum servo is, with the exception of the air filter and non return valve, a non-servicable sealed unit which if found to be faulty, must be replaced as an assembly. The air filter (surrounds the input push rod) should be replaced whenever the brake system is overhauled, and cleaned or replaced more frequently if the vehicle is operated in dusty conditions.
Page 230 Lotus Service Notes Section JJ Initial Movement Initial movement of the brake pedal causes the input rod to move to the right, and allows the control valve under the action of its spring, to close off the vacuum port in the driving piston. The atmospheric port remains closed.
Page 231 Lotus Service Notes Section JJ Pressure Balance Further pressure on the brake pedal opens the atmospheric port and bleeds atmospheric pressure into the left hand chamber. This pressure imbalance causes the driving piston to move to the right, adding assistance to the force applied directly to the output rod (and the master cylinder) via contact between the input and output rods.
Page 232 Lotus Service Notes Section JJ Maximum Assistance If the pedal is pressed hard, the atmospheric port will be held open, so that the left hand chamber will be subject to full atmospheric pressure. This is full servo assistance which will, with 0.8 bar of vacuum available from the engine, increase the force applied to the master cylinder pushrod by approximately four times.
Page 233 Lotus Service Notes Section JJ Operational Check As a quick check of servo operation proceed as follows: With the engine stopped, press the brake pedal several times to exhaust the servo unit of vacuum. Keeping the pedal pressed (which should be 'hard' and 'high'), start the engine;...
Page 234 Lotus Service Notes Section JJ JJ.11 - PEDAL BOX PRIOR TO '06 M.Y. The extruded and welded aluminium alloy pedal box is bonded and rivetted to an aperture in the chassis scuttle. A hollow steel pivot shaft serving all three pedals is bolted to a steel mounting plate, itself bolted to the inside of the pedal box.
Page 235: Clutch
Lotus Service Notes Section JJ Release the pedal return springs and remove the stop lamp switch. From above, release the six M6 screws securing the pedal shaft mounting bracket to the top of the pedal box, and the single screw in the front face of the pedal box. Withdraw the pedal shaft assembly from inside the pedal box.
Page 236 The Kelsey-Hayes antilock brake system is an 'add on' type used to supplement the dual circuit, tandem master cylinder, vacuum servo assisted brakes fitted to the Elise. A single electro-hydraulic unit comprising a hydraulic modulator, hydrauliic pump, microprocessor and solenoid valve bank, is mounted in the front serv- ices compartment and plumbed into the front and rear brake circuit lines from the tandem master cylinder.
Page 237 Lotus Service Notes Section JJ 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 238 Lotus Service Notes Section JJ 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 239: Brakes
Lotus Service Notes Section JJ 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 ener- gises the isolator valve solenoid, which closes the valve against spring pressure and maintains existing pres- sure in the left hand front brake circuit regardless of any increase in pedal pressure.
Page 240 Lotus Service Notes Section JJ 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 241 Lotus Service Notes Section JJ 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 242 Lotus Service Notes Section JJ 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 243 Lotus Service Notes Section JJ JJ.13 - ELECTRO-HYDRAULIC UNIT The electro-hydraulic unit is located on the driver's side in the front services compartment, and is flexibly mounted in a support frame via three isolator rubber bushes. The support frame itself is fixed to the front suspension damper top mounting bracket and windscreen frame butress via another three rubber bobbins.
Page 244 Bleed the unit using the procedure detailed in sub-section JJ.3. Verify correct connection by using the 'Lotus Scan' tool in actuator tests with the car on a wheel free lift. Check that operation of each solenoid valve affects the appropriate wheel.
Page 245 Data Link Connector (DLC), located at the front of the passen- ger footwell. Note that this tool may also be used on previous Elise models (excluding Exige '00 M.Y, 340R and 160 models).
Page 246 Lotus Service Notes Section JJ Downloading software from P.C. With early type adaptor lead Connect to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c With later type adaptor Connect to COM port on PC...
Page 247 Access to the diagnostic codes is available only by using the 'Lotus Scan' tool connected to the DLC (see JG.15). The ‘Lotus Scan’ is a hand held electronic scanner tool with an LCD display panel which is able to display any stored trouble codes and sensor readings as well as allowing manual operation of actuators.
Page 248 RR REL. SOL. CMD Rear right solenoid release command RR REL. SOL. FDBK Rear right solenoid release feedback ECU Identification The ECU identification number for the Elise/Exige is: A120J6000F Supplier ECU Hardware Number: EBC 430 Supplier ECU Software Number: LCFWDQ04K2K Page 33...
Page 249 Lotus Service Notes Section JJ Circuit Diagram Diagnostic Trouble Codes Page 34...
Page 250 C0561 Replace electronic control unit; C-02 C0563 Replace electronic control unit; C-02 C0564 Replace electronic control unit; C-02 C0800 Switched battery voltage: high (valve relay) C-03 low (valve relay) C-03 For remedial procedures, see Lotus Scan tool display. Page 35...
Page 251 Lotus Service Notes Section JJ FROM '06 M.Y. Introduced for the 2006 model year, was electronic throttle control (ETC), which dispensed with the mechanical throttle cable linking the accelerator pedal to the throttle body. The ‘drive by wire’ throttle actuation uses a throttle pedal fabricated from steel rod which is pivotted in a plastic housing bolted to the pedal box.
Page 252 Lotus Service Notes Section JJ JJ.8A - '08 MODEL YEAR UPGRADE OPTION Introduced as an option for some '08 models, is an uprated front brake kit, comprising 4-piston front callipers, larger diameter front discs and steel braided hoses. Front Callipers: At each front corner, the A.P.
Page 253 Lotus Service Notes Section KH ENGINE COOLING SECTION KH Sub-Section Page General Description KH.1 Maintenance KH.2 Drain/Refill Procedure KH.3 Radiator & Cooling Fan KH.4 Radiator Fan Control KH.5 Radiator Feed & Return Pipes KH.6 Water Pump & Thermostat See Section EH Oil Coolers KH.7...
Page 254 Lotus Service Notes Section KH Coolant Flow Circuits Thermostat closed Heater feed pipe in sill Throttle body Thermostat housing Heater matrix in climate k74b chamber Heater return Heater return pipe pipe in sill Heater feed from Header tank back of cylinder head...
Page 255 Lotus Service Notes Section KH KH.1 - GENERAL DESCRIPTION The engine cooling system comprises an engine driven water pump, a front mounted radiator with elec- tric cooling fan(s), a header tank, re-circulation pump and associated ducting, pipework and controls. The centrifugal water pump is mounted on the front face of the cylinder block, and is driven by the smooth 'back' side of the multi-rib auxiliary drive belt.
Page 256 In order to protect against these dangers as well as raising the boiling point of the coolant, the Elise 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 257 Lotus Service Notes Section KH To refill the system: Refit the hoses to the feed and return pipes and close the cylinder block drain tap. Remove the right hand front wheelarch liner and open the air bleed plug on the radiator outlet hose. From within the engine bay, open the air bleed plug in the heater return hose at the left hand rear of the engine bay.
Page 258 Lotus Service Notes Section KH Radiator Mounting Rear mounting Front mounting spreader plate spreader plate Radiator mounting panel Front mounting bracket Rear mounting bracket Engine cooling radiator Air conditioning condenser Fan fixing (if fitted) Cooling fan p105 Page 6...
Page 259 Lotus Service Notes Section KH Engine cooling radiator Front spreader plate Rear mounting Front mounting bracket bracket Radiator a.c. condenser mounting panel Cooling fan p106 KH.5 - RADIATOR FAN & RE-CIRC. PUMP CONTROL The two cooling fans are fitted beneath the radiator or (with a.c.) condenser/radiator package, and the coolant re-circulation pump is mounted below the header tank.
Page 260 Lotus Service Notes Section KH If the ECM receives a signal voltage outside of the acceptable range, a default setting equating to 60°C will be substituted, and the cooling fan energised. KH.6 - RADIATOR FEED & RETURN PIPES The radiator feed and return pipes are routed through the chassis main side rails, feed on the left, and return on the right.
Page 261 Lotus Service Notes Section KH exchanger to the heater water return pipe. This device transfers heat from the engine coolant to the oil after a cold start, and conversely, in conditions of high oil temperature transfers heat from the oil to the coolant.
Page 262 Lotus Service Notes Section KH Procedure for conversion from single to twin front mounted oil coolers Parts Required Part Number Oil Cooler, RH, incl. foam seal A120K0020F Duct, oil cooler, RH - Elise A120B0090F - Exige A122B0194F Big Head Pop Rivet, duct fixing A089W6297F Remove the front clamshell (refer to sub-section BR.6).
Page 263 Lotus Service Notes Section LK FUEL SYSTEM SECTION LK - ELISE for North America Sub-Section Page General Description LK.1 Fuel Filling LK.2 Precautions LK.3 Fuel Tank LK.4 Fuel Pump/Sender Assembly LK.5 Charcoal Canister LK.6 Fuel Tank Pressure Test LK.7 Page 1 sn_lk_croft.indd 1...
Page 264 Lotus Service Notes Section LK Page 2 sn_lk_croft.indd 2 03/03/2006 11:22:27...
Page 265 Lotus Service Notes Section LK LK.1 - GENERAL DESCRIPTION The 10.6 U.S. gall. (40 litre) fuel tank is fabricated from stainless steel, and is mounted within the chassis crossmember between the passenger compartment and engine bay, and is secured against foam mouldings by two support brackets from beneath.
Page 266 91 (RON+MON)/2 is recommended. Where super or premium fuel is not available, the Elise will operate satisfactorily on unleaded gasoline having a minimum rating of 87 (RON+MON)/2, but vehicle performance and economy will be reduced. Using fuel with a lower octane rating may cause knocking (pinking) which, if severe, can cause serious engine damage.
Page 267 Gasohol - A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in the Lotus Elise. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle is operated on gasoline.
Page 268 Lotus Service Notes Section LK Fuel Pressure Relief Procedure This procedure should be used prior to disconnecting any part of the fuel line. Pull out the fuel pump fuse (on the left hand side of the engine bay bulkhead, as shown), start the engine, and run until it stops from starvation.
Page 269 Lotus Service Notes Section LK To Remove Fuel Tank If possible, this operation should be performed when the fuel level is low to lighten the tank weight. WARNING: The fuel line between pump and engine remains pressurised after switching off the ignition.
Page 270 Lotus Service Notes Section LK L58b Fixing to chassis Fixing to sill Fuel tank 'shear panel' Support the tank before removing the two support cradles from the chassis. Each cradle uses two bolts at the front end of the bracket, and a single bolt at the rear, all threading into Rivnuts in the chassis.
Page 271 Lotus Service Notes Section LK Polypropylene saddles Fuel tank Foam sponge Rubber wedge Earth braid Support cradle L59b 11. Ensure the pump/sender unit, FLVV, roll-over valve and associated pipework is ﬁtted to the tank, with the earth braid ﬁtted onto the '10 O'clock' position pump mounting stud.
Page 272 Lotus Service Notes Section LK To Remove Pump/sender Assembly Clamp ring Remove the fuel tank (see sub-section LK.4). Spacer ring Release the eight nuts securing the clamping ring, and carefully withdraw the pump assembly from the tank. Immedi- ately seal the tank aperture to reduce the Pressure sensor vapour hazard and prevent dirt ingress.
Page 273 In order to verify the sealing integrity of the fuel tank and ﬁller system, the following test should be per- formed: Use the Lotus Scan tool to close the canister vent valve or apply 12 volts and ground to the two terminals of the vent valve electrical connector.
Page 274 Lotus Service Notes Section LK Other possibilities include: Poorly sealing fuel ﬁller cap. Check tightness, body foul conditions, sealing ring integrity. Pipe and hose connections. Canister close vent valve (CCVV). Check by clamping hose between canister and vent valve. A signiﬁcant improvement indicates a suspect valve.
Page 275 Lotus Service Notes Section MP ELECTRICS SECTION MP Sub-Section Page Cobra Vehicle Security Alarm (prior '08 M.Y.) MP.1 Central Door Locking MP.2 Electric Windows MP.3 Switches & Instruments - Driver's Information MP.4 Component Location & Fuse Ratings MP.5 Audio Equipment MP.6...
Page 276 Lotus Service Notes Section MP MP.1 - COBRA VEHICLE SECURITY ALARM The Lotus Elise/Exige prior to '08 M.Y. is ﬁtted as standard with a Cobra 8186 immobiliser/alarm which includes the following features: • Elise 111R U.K. approval to Thatcham category 1.
Page 277 Lotus Service Notes Section MP Two ﬂashes of the hazard warning lamps; Continuous ﬂashing of the security tell tale. Check that these indications occur. If not, press the button a second time, as the ﬁrst press may have only switched off the passive immobilisation (see above).
Page 278 Lotus Service Notes Section MP Manual Activation of Horn/Siren To enhance personal security, with the system in an armed state, the siren may be manually triggered by pressing the transmitter smaller button. The horn/siren will sound and the turn lamps ﬂash for 15 seconds. To stop the alarm, press either of the two buttons.
Page 279 Identiﬁcation of alarm controller Note that earlier Elise variants have used versions of the alarm controller with and without CDL function- ality. For Elise 111R and Exige models with CDL, the controller should be printed with the identiﬁcation 8185 4C8170AIB.
Page 280 The EXIGE AUXILIARY doors can be unlocked from outside only BATTERY POSTS after: Elise; opening the engine cover and restoring power to the battery by substitution, re-charging or ‘jumping’ to a second battery. Exige; removing the front body passenger side access panel and providing a 12 volt supply to the auxiliary power point.
Page 281 Lotus Service Notes Section MP MP.3 - ELECTRIC WINDOWS (if ﬁtted) On cars so equipped, switches for the electric windows are mounted in the front of the door trim panels, and are operative only with the ignition switched on. To help locate the switches in the dark, an illuminated dot is provided in the ‘down’...
Page 282 Lotus Service Notes Section MP MP.4 - SWITCHES & INSTRUMENTS - DRIVER'S INFORMATION Ignition Switch/Steering Lock The switch/lock is located on the right hand side of the steering column. Insert the key into the slot, and turn clockwise to position ‘I’ to unlock the steering column. If the key is reluctant to turn, wriggle the steering wheel to ease the load on the steering lock.
Page 283 Lotus Service Notes Section MP Seat Belt Tell Tale (b) The red seat belt tell tale is provided as a reminder that both driver and passenger should always wear the seat belts, no matter how short the journey. The lamp will light for about 8 seconds following ignition switch on, before being extinguished.
Page 284 In order to comply with emissions regulations, data regarding activation of the MIL is recorded in the engine electronic controller, and may be downloaded by Lotus dealers. Security/RPM Tell Tale The security tell tale is located at the top of the tachometer display, and indicates the status of the im- mobiliser and alarm.
Page 285 Lotus Service Notes Section MP LCD Panel A liquid crystal display (LCD) panel is provided below the instruments in order to display fuel level, coolant temperature, total mileage and trip functions. The panel is blank until the ignition is switched on.
Page 286 Lotus Service Notes Section MP Lights On’ Buzzer A ‘lights on’ reminder buzzer will sound if the lights are on when the ignition is switched off and the driver’s door is opened. Sidelamps Headlamps Rear Fog ohs109a Rear Fog Lamp Switch The lowermost switch controls the two rear fog lamps (where ﬁtted), and may be selected only after ﬁrst...
Page 287 Lotus Service Notes Section MP WARNING: Do not leave small children unattended in the car since careless interference with the power socket could be dangerous. Headlamp Dipswitch/Flasher/Turn Indicators The steering column left hand lever switch controls the headlamps main beam/dip, headlamp ﬂash and turn indicators.
Page 288 Twenty two slots are provided for ‘Littel’ type fuses which are numbered, and coloured according to their am- perage rating, and may be pulled out from their slots using the fuse extractor tool provided on the fusebox lid. m254 As viewed from in front of Elise: Fuse 1 Fuse 11...
Page 289 Lotus Service Notes Section MP Engine Compartment ENGINE BAY FUSES Fuses and relays associated with the engine management system are contained in two 4-position fuse holders located at the front of the engine bay on the cabin bulkhead, adjacent to the engine ECM. To access the fuses, unclip rear edge of the cover.
Page 290 Flasher unit Wiper delay MP.6 - AUDIO EQUIPMENT Front speaker The Elise may be speciﬁed with various audio equipment options. All cars are ﬁtted with a main wiring harness which includes: an ISO 16-way connector located behind the standard ISO size audio aperture in the dash panel;...
Page 291 Lotus Service Notes Section MP Speaker speciﬁcations are as follows: Rear: Blaupunkt GTX 542 2-way co-axial; 90W max; 30W RMS; 4 ohms impedance. Front: Blaupunkt TSX 402 2-way co-axial; 105W max; 35W RMS; 4 ohms impedance. To remove the rear bulkhead trim panel, remove the four screws securing the top edge of the panel to the bulkhead plinth, and ease the panel from behind the seat belt mounting frame at each side.
Page 292 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 charger such as that available through Lotus After Sales. Such devices, when connected to a vehicle battery, continuously monitor battery charge state and switch on and off automatically in order to maintain the battery in a fully charged state without danger of damage through overcharging.
Page 293 Lotus Service Notes Section MP Battery cables; positive & negative posts Positive binding post on scuttle Chassis front earthing point Starter solenoid Battery negative Battery positive m191b Chassis rear earth point Positive post on bulkhead Chassis Chassis front earth To ECU...
Page 294 Lotus Service Notes Section MP MP.8 - WIPER MECHANISM The windscreen wiper mechanism comprises a uni-directional motor with an external rotary link, a con- necting rod, and a pair of actuating links which join the connecting rod to the arms of the wiper spindle. This mechanism provides the wiper with a motion which is slowed at each end of its travel in order to ease the inertia loads during direction changes, to the beneﬁt of reﬁnement and durability.
Page 295 Lotus Service Notes Section MP RHD Shown (LHD symmetrically opposite) Wiper linkage in full travel position m209 Re-assemble in the reverse order to removal, torque tightening the bracket bolts to 20 Nm. MP.9 - HARNESS ROUTING The main harness runs from the main fusebox/relay station at the passenger side of the front services compartment, and divides into three branches;...
Page 296 Lotus Service Notes Section MP MP.10 - FRONT LAMP ASSEMBLIES Headlamp Units - Prior '07 M.Y. The front clamshell incorporates, at each side, a headlamp housing, in each of which are mounted a halo- gen projector type dip beam lamp (upper), and a halogen main beam lamp (lower), which also incorporates the sidelamp bulb.
Page 297 Lotus Service Notes Section MP accessed from behind the lamp. Turn clockwise to adjust the beam to the right. - To adjust the vertical aim of the main beam, adjust the dome headed screw at the lower outboard side of the lamp, accessed from behind the lamp. Turn clockwise to raise the beam.
Page 298 Lotus Service Notes Section MP To remove a lamp unit from the car, remove the three M10 nuts and the single M6 nut securing the lamp assembly to the clamshell. On re-assembly, note that the jointline between lamp and body may be optimised via threaded collars on three of the lamp ﬁxing studs.
Page 299 WARNING: • When an LSD is ﬁtted, Lotus Traction Control should always be active when driving on the public highway in normal conditions. • If the system is switched off when driving off-highway, be aware of the consequent change in vehicle behaviour and modify driving style accordingly.
Page 300 Lotus Service Notes Section MP Fuses m254 As viewed from in front of Elise: Fuse 1 Fuse 11 m255 Fuse 12 Fuse 22 MAIN FUSEBOX Slot Rate Circuit Supply Slot Rate Circuit Supply Aux. power socket Battery Rad. fans; Battery...
Page 301 Battery LED Rear Lamps Introduced on all 6-speed Elise variants for ’06 M.Y. are new rear lamp clusters incorporating LEDs in the annular segments of the lamps. The central elements continue to use ﬁlament bulbs. The non-USA Elise also adopts the USA centre high mounted stop lamp (CHMSL) featuring red LEDs behind a white lens. The light emitting diodes are extremely durable and are serviced only by lamp cluster replacement.
Page 302 Lotus Service Notes Section MP MP.12 - 2008 M.Y. SUPPLEMENT VEHICLE SECURITY ALARM The Lotus Elise/Exige for ‘08 model year onwards is ﬁtted as standard with a PFK 457 immobiliser/alarm which includes the following features: • Lotus branded transmitter key.
Page 303 Lotus Service Notes Section MP Passive Immobilisation In order to provide a measure of automatic vehicle security, independent of any driver initiative, the sys- tem will ‘passively’ immobilise the engine’s cranking and fuel pump circuits after the ignition has been turned off for 40 seconds, or a similar period has elapsed since the last mobilising command.
Page 304 Lotus Service Notes Section MP The sensitivity of the sensor is factory set for the Elise/Exige, and should never need Adjuster screw any adjustment. Such a faciltity is, however, provided on the unit, and is accessible after removal of the cabin rear bulkhead trim panel.
Page 305 Lotus Service Notes Section MP 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. Programming Additional Transmitters A maximum of 6 transmitters may be programmed to the car, any thereafter overwriting the ﬁrst to have been programmed.
Page 306 Maximum transient engine speed in all gears at normal running temperature, is 8,500 rpm (7150 rpm for Elise S), at which point the engine is governed, but as the rate of rpm increase is potentially greater in the lower gears, the tell tale trigger points are tailored to accommodate the reaction time available. As maximum...
Page 307 Lotus Service Notes Section MP Tachometer Service tell tale Speedometer High rpm Security tell tale tell tales �� LCD panel Traction control Low tyre pressure ohs127b tell tale tell tale The engine is not protected from overspeeding caused by erroneous or premature downchanging. Such misuse could result in catastrophic failure, not covered by the vehicle warranty.
Page 308 VARIABLE TRACTION & LAUNCH CONTROL (IF FITTED) Exige S models speciﬁed with the ‘Performance Pack’ option, include variable Lotus Traction Control (LTC), allied with Variable Launch Control (see below) and have a rotary control knob mounted on the left hand side of the steering column shroud.
Page 309 This has been commonised for all Elise/Exige models. The Lotus Scan 3 tool is replaced by a 'stand alone' lap top PC loaded with 'Lotus Techcentre' software to allow the CAN based serial data to be read. An '08 model year update kit T000T1494F will shortly be issued mandatorily to all dealers. The Vehicle Communication Device (T000T1476F) introduced for the Europa model is used to connect the vehicle to the laptop Lotus Techcentre.
Page 310 Lotus Service Notes Section MP MP.13a - CIRCUIT DIAGRAMS - non USA, prior '06 M.Y. Circuit Sheet Start, Alternator, Ignition Fuel Pump, Engine Management 1 Engine Management 2, Diagnostic Connector Engine Management 3 Alarm, Interior Lamp Stoplamps, Reverse Lamps Direction Indicators, Hazard Lamps...
Page 311 Lotus Service Notes Section MP MP.13b - CIRCUIT DIAGRAMS - USA prior '06 M.Y. Circuit Sheet Start, Alternator, Ignition Fuel Pump, Engine Management 1 Engine Management 2, Diagnostic Connector Engine Management 3 Alarm, Interior Lamp Stoplamps, Reverse Lamps Direction Indicators, Hazard Lamps...
Page 312 Lotus Service Notes Section MP MP.13c - CIRCUIT DIAGRAMS - '06 M.Y. onwards Circuit Sheet Colour Code & Abbreviations Page 32 Start, Alternator, Ignition Fuel Pump, Engine Management 1 Engine Management 2, Diagnostic Connector Engine Management 3 Alarm, Interior Lamp...
Page 313 Lotus Service Notes Section MP Colour Code B = Black G = Green K = Pink LG = Light Green N = Brown O = Orange P = Purple R = Red S = Slate U = Blue W = White...
Page 314 Lotus Service Notes Section MP MP.13d - CIRCUIT DIAGRAMS - '08 M.Y. onwards Circuit Sheet Page Colour Code & Abbreviations Start, Alternator, Ignition Fuel Pump, Engine Management 1 Engine Management 2, Diagnostic Connector Engine Management 3 Alarm, Interior Lamp Stoplamps, Reverse Lamps, Tyre Pressure Monitoring...
Page 315 Lotus Service Notes Section MP Colour Code B = Black G = Green K = Pink LG = Light Green N = Brown O = Orange P = Purple R = Red S = Slate U = Blue W = White...
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Page 367 Lotus Service Notes Section OI MAINTENANCE & LUBRICATION SECTION OI Page Recommended Lubricants Maintenance Schedule - Elise 111R & '04 Exige (non-USA) - Elise/Exige North America Pre-Delivery Inspection Body Paint Inspection - Elise - Exige Licence Plate Fitment Page 1 sn_oi_cyclone.indd 1...
Page 368 If Texaco/Havoline products are not available, an oil meeting the following speciﬁcation should be used. Note that Lotus does not recommend the use of any oil additives: Viscosity:...
Page 369 4. Thorough safety check including wheels, tyres, suspension, steering and brake systems. 5. The Lotus Elise and Exige are designed as road going sports cars. It is recognised that owners may wish to use the car occassionally on closed circuit tracks to experience the car's full range of dynamic capabilities.
Page 370 Lotus Service Notes Section OI lsl460a sn Page 4 sn_oi_cyclone.indd 4 03/03/2006 11:24:17...
Page 371 Lotus Service Notes Section OI 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 372 4. Thorough safety check including wheels, tyres, suspension, steering and brake systems. 5. The Lotus Elise is designed as a road going sports car. It is recognised that owners may wish to use the car occassionally on closed circuit tracks to experience the car's full range of dynamic capabilities. However, use of the car in a competitive manner, including timed runs or laps, is not endorsed by Lotus.
Page 373 Lotus Service Notes Section OI lsl462 sn Page 7 sn_oi_cyclone.indd 7 03/03/2006 11:24:17...
Page 374 Lotus Service Notes Section OI 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 375 4. Thorough safety check including wheels, tyres, suspension, steering and brake systems. 5. The Lotus Elise and Exige are designed as road going sports cars. It is recognised that owners may wish to use the car occassionally on closed circuit tracks to experience the car's full range of dynamic capabilities.
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Page 377 Lotus Service Notes Section OI 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 ............…………………………………………………………………………………..
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Page 382 LSL480 Front The Elise front clamshell incorporates a moulded plinth for the front licence plate. A licence plate mounting frame is supplied loose with the car for those States which require front plates. The aluminium frame has four M6 threaded studs, and should be ﬁtted to the clamshell plinth by marking and drilling the four 6mm clearance holes symmetrically about the vertical and horizontal centrelines of the plinth.
Page 383 Lotus Service Notes Section OI Page 17 sn_oi_cyclone.indd 17 03/03/2006 11:24:21...
Page 384 Lotus Service Notes Section PL AIR CONDITIONING, HEATING & VENTILATION SECTION PL Sub-Section Page General Description PL.1 Controls Operation & Airflow Distribution PL.2 Cooling Fans & Re-circulation Pump PL.3 Refrigerant Handling PL.4 Refrigerant Pipework Precautions PL.5 Refrigerant Oil PL.6 Compressor PL.7...
Page 385 Lotus Service Notes Section PL Heater Circuit Water feed pipe along outside of RH chassis siderail Heater matrix Water return pipe along outside of Water return to LH chassis siderail engine side of thermostat p77c Coolant re-circulation pump Refrigerant Circuit Receiver-drier Feed &...
Page 386 Lotus Service Notes Section PL PL.1 - GENERAL DESCRIPTION Heater System The heater system uses engine coolant to provide a heat source transferred to the interior airstream via a heat exchanger matrix mounted in an 'air blend' unit housed within the chassis well, ahead of the cabin footwell.
Page 387 Lotus Service Notes Section PL Compressor When the engine is running, and the refrigeration controls demand it, the electromagnetic clutch incorpo- rated in the compressor pulley is energised, which then locks the pulley to the shaft and drives the compressor.
Page 388 Lotus Service Notes Section PL PL.2 - HEATER/A.C. AIRFLOW OVERVIEW The major units of the Heating Ventilation and Air Conditioning (HVAC) system comprise a dual intake blower fan, an evaporator housing (with no evaporator fitted for non a.c. cars), a heater housing and an airflow distribution unit.
Page 389 Lotus Service Notes Section PL Airflow through a.c./heater unit Cold air Trunking to distribution unit Ambient or re-circulated air inlet p110b Heater Fan blower matrix a.c. evaporator (if fitted) Warm air Flap in full warm position p110a Butterfly flap open...
Page 390 Lotus Service Notes Section PL Interior Climate Controls The interior climate controls consist of INTERIOR CLIMATE CONTROLS two push switches (if fitted) for air condition- ing and air re-circulation, and three rotary con- trols for heater temperature, fan speed, and air distribution.
Page 391 Lotus Service Notes Section PL Face Level): Turned fully counterclockwise, the step- per motor on the air distribution unit (ADU) operates the rotary flap to close off the wind- screen vents, and direct all airflow to the four face level vents, each of which may be ma- nipulated to adjust volume and direction.
Page 392 Lotus Service Notes Section PL Footwell: As the control is turned clockwise from the face level vents symbol towards the footwell symbol, the stepper motor turns the rotary flap to progressively close off the face level vents. A rod connecting the rotary flap...
Page 393 Lotus Service Notes Section PL Demist: As the control is turned clockwise from the face level vents symbol towards the footwell symbol, the stepper motor turns the rotary flap to progressively open the wind- screen vents. The rod connecting the rotary...
Page 394 Lotus Service Notes Section PL PL.3 - COOLING FANS & RE-CIRCULATION PUMP The two cooling fans are fitted beneath the radiator or (with a.c.) condenser/radiator package, and the coolant re-circulation pump is mounted below the header tank. Both the fans and pump are controlled by the engine management ECU using data provided by the engine coolant temperature sensor mounted in the back of the cylinder head.
Page 395 Lotus Service Notes Section PL Seat belt mouting frame backstay Outlet from pump to heater Coolant header tank Wiring harness Coolant re-circulation pump p109b Heater return hose Heater feed from cylinder head Fans/compressor relay module Shelf on driver's side wheelarch liner...
Page 396 On no account should refrigerant ever be discharged to atmosphere - use a refrigerant recovery/recycling station in accordance with the manufacturer's instructions. Filling points on early Elise are located in the front services compartment, and on the Exige and later Elise, ahead of the RH rear wheel, accessible after removal of the wheelarch liner.
Page 397 Lotus Service Notes Section PL Refrigerant Pipework Fixing Torques Description Thread Pitch Torque Compressor to engine 35 Nm A.C. hoses to compressor 10 Nm Bulkhead connector, high pressure 3/4 - 16 UNF 25-30 Nm Bulkhead connector, low pressure 1 1/16 - 14 UNS...
Page 398 Lotus Service Notes Section PL PL.6 - REFRIGERANT OIL The internal working parts of the compressor are lubricated by refrigerant oil. This is a special type of oil which has an affinity with the refrigerant, such that a proportion of the oil circulates with the refrigerant, around the whole system.
Page 399 Lotus Service Notes Section PL PL.7 - COMPRESSOR The a.c. compressor is mounted on the left hand side of the cylinder block, beneath the alternator, and is accessible from below. A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump, alternator and a.c.
Page 400 Lotus Service Notes Section PL Compressor Fitment Fit the compressor to the engine and secure with the three M8 bolts; Tighten to 25 Nm (18 lbf.ft). Using a six-sided socket on the tensioner arm, fit the drive belt onto the compressor pulley.
Page 401 Lotus Service Notes Section PL PL.8 - CONDENSER The engine cooling radiator, a.c. condenser and cooling fans are secured together as a package and are mounted horizontally, with fans lowermost, on top of the crash structure. The all aluminium condenser is of parallel flow construction, with tanks at each side which direct the refrigerant flow from the front inlet connec- tion successively through 10, 7, 5 and 4 rows, before it emerges from the rear outlet union.
Page 402 Lotus Service Notes Section PL Front mounting spreader plate Rear mounting spreader plate Radiator mounting panel Front mounting bracket Rear mounting bracket Engine cooling radiator Air conditioning condenser Fan fixing Cooling fan p105 Page 19...
Page 403 Lotus Service Notes Section PL Release the radiator mounting panel from the crash structure and lift away the complete assembly. To remove the radiator pack from the mounting panel, pull out the sealing foam, release the three bolts securing each rear bracket to the panel, and the two bolts fixing each front bracket to the panel. Separate the fans, condenser and radiator as necessary.
Page 404 Lotus Service Notes Section PL Release the two M5 screws from the counterbored holes in the top of the valve, securing the valve to the evaporator pipes, and withdraw the valve from the pipes. Immediately cap the pipes and ports to prevent the ingress of dirt and moisture.
Page 405 Lotus Service Notes Section PL To remove heater/evaporator/fan unit: Remove the front clamshell (see sub-section BR.6). Remove the two air deflector/water shields, windscreen washer reservoir and ducting between heater/ a.c. unit and air distribution unit. Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of the engine bay.
Page 406 Lotus Service Notes Section PL Refit in reverse order to removal, ensuring that the sealing foam between the unit and baffle panel and on the chassis scuttle is present and in good condition. Secure by re-rivetting the retaining bracket. PL.13 - REFRIGERANT PIPES...
Page 407 Lotus Service Notes Section PL Hot air dam Gutter extension panel Radiator inboard fixing sb79 Page 24...
Page 408 Lotus Service Notes Section QH CLUTCH SECTION QH Sub-Section Page General Description QH.1 Clutch Pedal QH.2 Hydraulic Release System QH.3 Clutch Assembly QH.4 Page 1...
Page 409 Lotus Service Notes Section QH Page 2...
Page 410 Lotus Service Notes Section QH QH.1 - GENERAL DESCRIPTION The driving element of the clutch assembly consists of the rear face of the engine flywheel, and a pres- sure plate fixed to the flywheel via the spring diaphragm clutch cover assembly. The driven element, is a single, dry, double sided friction plate, splined to the gearbox input shaft, and interposed between the flywheel and pressure plate.
Page 411 Lotus Service Notes Section QH Pedal box Connection to fluid reservoir Clutch master cylinder Mounting bolt Pedal pushrod Clutch pipe connector Slave Cylinder The slave cylinder is secured by two bolts directly to the clutch housing on the forward side of the unit, and operates the clutch fork by a fixed length pushrod.
Page 412 Lotus Service Notes Section QH To replace the slave cylinder: Clean the slave cylinder and surrounding area with methylated spirit. Do not use petrol or paraffin. Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
Page 413 Lotus Service Notes Section QH Clutch master cylinder Dash baffle panel Steel pipe Slave cylinder Steel pipe clipped q46a to heater pipe Flexible hose to engine QH.4 - CLUTCH ASSEMBLY The clutch assembly comprises the friction plate, clutch cover assembly (pressure plate/diaphragm spring/ cover) and release bearing.
Page 414 Lotus Service Notes Section QH Friction plate: Check the cush drive springs for breakage or cracking of the hub. Examine the condition of the friction material for signs of oil contamination, scorching, or any other damage. Using vernier callipers, measure the depth of the rivet heads below the surface of the friction material. Minimum depth: 0.3mm.
Page 415 Lotus Service Notes Section QH Clutch housing to engine fixings - viewed from gearbox side M12x55 flange head bolts to block; 64 Nm M10x65 bolts also secure M10x55 bolts to starter motor; 37 Nm block; 37 Nm f134 M10x30 bolts to sump; 23 Nm...
Page 416 Lotus Service Notes Section WD AIRBAG SYSTEM SECTION WD - ELISE NORTH AMERICA Sub-Section Page General Description WD.1 Airbag Tell Tale WD.2 Data Link Connector WD.3 Trouble Codes WD.4 Lotus Scan Tool WD.5 Safety Precautions, Shipping, Storage & Disposal WD.6 Theory of Operation WD.7...
Page 417 Section WD WD.1 - GENERAL DESCRIPTION The Lotus Elise for USA markets, introduced for 2005 model year, is equipped with a driver and passen- ger frontal airbag system, which includes pyrotechnic seat belt pre-tensioners for both the driver and passen- ger.
Page 418 In order to provide for communication with the airbag SDM, engine management system ECU and anti- lock brake system, a hand held electronic scanner 'Lotus Scan 2' (part number T000T1418F), may be plugged into the Data Link Connector (see earlier)
Page 419 Lotus Service Notes Section WD Downloading software from P.C. With early type adaptor lead Connect to COM Power port on PC supply transformer Adaptor lead used to connect to transformer em192c With later type adaptor Connect to COM port on PC...
Page 420 Sensor & Diagnostic Module (SDM) The SDM is calibrated specifically to the Elise, and is mounted on a dedicated bracket to the scuttle beam. Never use an SDM from another vehicle, or modify its mounting to the Elise. WARNING: •...
Page 421 Lotus Service Notes Section WD Airbag Activation/Disposal Procedure Items Required People. 2 Pairs Heat proof gloves. 2 Pairs Eye protection glasses. 2 Pairs Ear defenders. Explosion container – a container to constrain the sudden inflation of the bag, may be mesh e.g. metal stillage, but requires a lid.
Page 422 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 423 Lotus Service Notes Section WD Inspections Required After an Accident All SRS system components, including harnesses and brackets, must be inspected after an accident. If any are damaged or bent, they must be replaced even if a deployment did not occur.
Page 424 Lotus Service Notes Section WD • Fault storage and 'Crashrecording' within EEPROM ('crashrecording': recording of system parameters (e.g. fault status in deployment events). • Diagnostic communication using an ISO9141 protocol. Frontal Impact Sensing and Deployment The SDM contains an integrated accelerometer which provides a nearly linear proportional electrical representation of the acceleration experienced by the vehicle along the longitudinal axis.
Page 425 The only permitted repair to the airbag door and tether strap assembly is the replacement of the plastic retaining clips which secure the door to the dashboard. If the clips are broken, they MUST be replaced ONLY by the correct Lotus supplied parts. Do not attempt to fix the door in position by any other means.
Page 426 Lotus Service Notes Section WD Centre vent panel and radio surround: Release the two screws at each side of the panel and withdraw. Fascia top panel: Remove the 5 screws securing the rear edge of the panel to the dash rail, and withdraw the panel rearwards to disengage the two spigots from the base of the windscreen surround.
Page 427 Lotus Service Notes Section WD the yellow harness connector. WARNING: When carrying a live airbag module, make sure the bag and trim cover are pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury.
Page 428 Lotus Service Notes Section WD and bear directly against the hub, without interfering with the rotary connector. The centre screw should bear against the end of the column. Withdraw the wheel/hub/rotary connector assembly from the column splines. Alternatively, for better puller access, the steering wheel can first be removed from the hub by releasing the four retaining screws.
Page 429 Lotus Service Notes Section WD WARNING: The harness connector for the passenger's airbag is accessible only after removing the fascia top panel, so care should be taken to avoid working in close proximity to the airbag door in case of unintended deployment.
Page 430 Lotus Service Notes Section WD WD.12 - SEAT BELT PRE-TENSIONERS WARNING: • Failure to comply with the instructions, safety standards and operating procedures as described in this section, may cause vehicle damage and/or personal injury. • Both driver and passenger seat belt assemblies must be replaced after SRS deployment. Do not attempt to repair or reuse.
Page 431 Lotus Service Notes Section WD Removal of Seat Belt Assembly WARNING: Before removing or refitting a pyrotechnic seat belt assembly, the ignition key should be withdrawn, and the battery leads disconnected from both positive and negative terminals, and iso- lated to ensure that accidental contact cannot occur.
Page 432 Lotus Service Notes Section WD Safety Standard The pre-tensioning function is energised via pyrotechnic materials, therefore manipulation, handling and storage MUST be performed to the specified procedures as described to avoid any occurrence of injury to the operator or damage to the pre-tensioning unit.
Page 433 WARNING: The seat belt pre-tensioner devices fitted on the Lotus Elise 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.
Page 434 Lotus Service Notes Exige S/C SUPPLEMENT EXIGE SUPERCHARGED (S/C) Sub-Section Page Concept & Overview Exige S/C.# Technical Data Exige S/C.TD Body Exige S/C.B Front Suspension Exige S/C.C Rear Suspension Exige S/C.D Engine Exige S/C.E Wheels & Tyres Exige S/C.G Brakes Exige S/C.J...
Page 435 Lotus Sport workshops at Hethel, and available for the U.K. and certain overseas territories where regula- tions allow. In November 2005, Lotus Sport commenced build of a limited number of Exige Cup 240 cars in road or race speciﬁcation for selected markets, and differing in detail to the 240R. Then in January 2006, an ofﬁcial production version of the supercharged car, Exige S, was introduced with a simpliﬁed speciﬁcation.
Page 436 Lotus Service Notes Exige S/C EXIGE S/C.TD - TECHNICAL DATA Where different to standard Exige: Engine Forced induction Magnuson MP62 supercharger with integral by-pass valve. Air/air chargecooler. Maximum boost pressure 0.5 bar (7 psi) Max. power - 240R & Cup 181 kW (243 bhp;...
Page 437 Each Lotus Sport Exige 240R is individually numbered from 001 to 050, and identiﬁed by a Lotus Sport build plate styled after those used by Team Lotus for the Formula One cars. The plate is riveted to the chassis main side rail on the passenger side, and is engraved with the unique Limited Edition number.
Page 438 Lotus Service Notes Exige S/C EXIGE S/C.C - FRONT SUSPENSION - 240R & CUP Stiffened road springs front and rear are ﬁtted on new Ohlins dampers featuring remote gas reservoirs, adjustable spring platforms and separate adjustments for compression and rebound damping. The spring plat- forms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compression and 60 rebound damper settings allow the characteristics to be ﬁne tuned to individual requirements.
Page 439 Lotus Service Notes Exige S/C Page 6 sn_Exige Supercharged supplement.indd 6 03/03/2006 11:32:35...
Page 440 Lotus Service Notes Exige S/C Chargecooler outlet duct Inlet manifold Chargecooler Chargecooler inlet duct Boss for 5th injector Standard (240R) airbox Supercharger outlet elbow Supercharger outlet adaptor Electronic Supercharger throttle body FRONT Throttle body adaptor le2047a Flexible bellows Adaptor to chargecooler...
Page 441 Cup cars use 4 special high-ﬂow port injectors, and Exige S cars retain stand- ard injectors. The Lotus engine management system is reprogrammed to suit each engine speciﬁcation and incorporates additional functions to control the ﬁfth injector (240R) and supercharger by-pass valve. The boost characteristics have allowed the switching point from low to high lift cam proﬁle to be reduced from 6,000 to...
Page 442 Lotus Service Notes Exige S/C Accusump reservoir Air pressure gauge EPC valve assembly FRONT Mounting clamp to boot ﬂoor In-line ﬁlter To LH port From oil on sandwich cooler plate pl4015cLR Before checking the oil level, the Accusump pre-charge pressure should ﬁrst be checked; turn on the ignition to open the EPC valve and allow the stored oil to be discharged from the Accusump.
Page 443 Lotus Service Notes Exige S/C Supercharger Remove/Reﬁt To remove: Remove the chargecooler together with inlet and outlet 'U' shaped ducts. Remove the throttle body and vacuum/breather hose plumbing. Using a 6-point socket, relieve auxiliary belt tension and remove the auxiliary belt. Remove the alternator top mounting bolt, slacken the lower, and swing down the alternator.
Page 444 Exige wheels, but retain the standard insets of + 31.3 mm and + 38.0 mm. The wheels are ﬁnished in either Satin Black or High Power Silver dependent on body colour (see above). 'Lotus Sport' is moulded into one of the spokes of each wheel. Cup and Exige S models use standard Exige wheels ﬁnished in hi-power silver.
Page 445 Lotus Service Notes Exige S/C EXIGE S/C.O - MAINTENANCE & LUBRICATION A Maintenance Schedule for supercharged cars is available under part number LSL460b. Recommended lubricants are unchanged apart from: 240R & Cup cars: Brake Fluid; Castrol SRF Fuel; Unleaded 98 RON Spark plugs are part number ALS3E6015F (NGK PFR7G) with 0.8mm (- 0.1, + 0) gap.
Page 446 Lotus Service Notes Exige S/C EXIGE S/C.X - RETROFITMENT OF SUPERCHARGER To retroﬁt the Magnuson MP62 supercharger and related engine systems to the standard Exige, proceed as follows. Note that throughout this section, the terms 'front', 'rear', 'left' and 'right' when referring to engine components are used in the convention of the ﬂywheel end of the engine being the rear.
Page 447 Lotus Service Notes Exige S/C manifold. Fit the new manifold and retain with the original two top ﬁxings using Permabond A130. Do not fully tighten. Use new ﬂange head bolt A116W5238F with Permabond A130 at the rearmost ﬁxing point. Take the nut previously ﬁtted on the foremost stud, and ﬁt instead to the new stud at the centre bottom ﬁxing...
Page 448 Lotus Service Notes Exige S/C use a strap wrench to hold the pulley whilst the nut is tightened to 61 Nm. 20. Use a 6-point socket on the tensioner arm to allow ﬁtment of the new multirib accessory drive belt around the pulleys as shown, ensuring that the belt is correctly seated in all the ribbed pulleys.
Page 449 Lotus Service Notes 2-Eleven SUPPLEMENT 2-Eleven Sub-Section Page Concept & Overview 2-Eleven.# Technical Data 2-Eleven.TD Chassis 2-Eleven.A Body 2-Eleven.B Front Suspension 2-Eleven.C Rear Suspension 2-Eleven.D Engine 2-Eleven.E Wheels & Tyres 2-Eleven.G Brakes 2-Eleven.J Cooling 2-Eleven.K Fuel System 2-Eleven.L Electrical 2-Eleven.M Maintenance &...
Page 450 2-Eleven 2-ELEVEN.# - CONCEPT & OVERVIEW In March 2007, Lotus announced the Lotus 2-Eleven (255 PS) designed for the motorsport enthusiast, and aiming to provide a high fun factor from a lightweight, high performance, distinctively styled vehicle, suitable as a basis for various sporting disciplines, as well as offering U.K. customers the option of a unique road going experience.
Page 451 Lotus Service Notes 2-Eleven 2-ELEVEN.TD - TECHNICAL DATA (Where different to standard naturally aspirated Exige) Identiﬁcation The VIN coding of the 2-Eleven includes the following identifying characters: Character 4 (engine type); 2-Eleven 2ZZ supercharged 255 bhp = N Character 6/7/8 (vehicle type); 2-Eleven = 123 Character 12 (chassis speciﬁcation);...
Page 452 Lotus Service Notes 2-Eleven Suspension General Unique front top wishbones and steering arms. Chassis rear brace Ride height, mid-laden, front/rear 100/110 (2 x 75 kg pass., ½ tank fuel) Option Siffened, 5-position adjustable front anti- roll bar with Ohlins gas pressurised, 2-way adjustable, remote reservoir damp ers, with adjustable spring top platforms.
Page 453 Addition of a body side attachment panel to the lower edge of each chassis rail sill extension. The front crash structure is as Elise/Exige with minor fettling revisions, and the galvanised steel rear subframe differs only in respect of incidental ﬁxings.
Page 454 Note: The 2-Eleven is not equipped with conventional shock absorbing bumpers, so extra care should be taken when parking to guard against body damage. The Lotus 2-Eleven does not offer the same kind and degree of impact resistance or energy absorption afforded by normal bumper systems. Some panels, including the front quarter panels and ‘A’...
Page 455 Lotus Service Notes 2-Eleven At each side, two screws pass through the transom end ﬂange into captive nuts in the body side panel. Rear Scuttle Panel The rear scuttle panel is ﬁxed at each side by two horizontally disposed M6 screws into bond nuts on the body side panel, and is bonded along the top edge of the rear bulkhead.
Page 456 Exterior The Launch Edition of the 2-Eleven is ﬁnished in a two tone combination of B111 Lotus Sport Black and B115 Arctic Silver, with yellow/black/silver styling decals. A '2 Eleven' decal is applied to the rear transom panel, with optional larger decals on each body side. Stone chip ﬁlm is ﬁtted to vulnerable areas.
Page 457 2-Eleven 2-ELEVEN.C - FRONT SUSPENSION The front suspension is based on standard Elise/Exige componentry, but the angle of the top wishbone ball joint housing differs to better suit the lowered ride height. For the same reason, re-conﬁgured steering arms are ﬁtted, being machined from solid EN16 steel billets, and heat treated.
Page 458 Lotus Service Notes 2-Eleven Compression (bump) damping is adjust- ed by turning the knob on the end of the gas reservoir canister: Turn clockwise to increase damping, and couterclockwise to decrease. Recommended settings are as follows: Road use: 15 clicks from full hard...
Page 459 The 1.8 litre 2ZZ-GE engine with VVTL-i (Variable Valve Timing and Lift - intelligent) as used in other Elise/Exige models, is ﬁtted with a low pressure Roots type Magnuson MP62 supercharger to provide up to 0.5 bar (7 psi) of boost pressure. The supercharger is mounted on the left hand side of the block and driven by a lengthened version of the multirib auxiliary belt.
Page 460 Lotus Service Notes 2-Eleven Connection to chargecooler Chargecooler inlet duct outlet & inlet New inlet manifold Supercharger outlet connector Supercharger outlet elbow Supercharger outlet adaptor Mounting lug Swan neck for supercharger adaptor ﬁxings Chargecooler Fixing point (s/c inlet) outlet duct...
Page 461 Lotus Service Notes 2-Eleven A one-way valve at the oil cooler connection of the 'T'- piece ensures that the oil discharged from the Accusump is directed into the oil pump and not the cooler. An Electric Pressure Control (EPC) valve ﬁtted at the connection to the Accusump cylinder, allows cylinder charging when oil pressure is above 35 - 40 psi, and cylinder discharging at engine oil pressures below 35 - 40 psi.
Page 462 Lotus Service Notes 2-Eleven The oil can then be drained in the usual way, with the quantity contained in the oil cooler lines disregarded for the purposes of routine maintenance. If an engine failure has occurred, with possible debris contamination of oil hoses and coolers, it is recommended to replace both oil coolers, and to replace or thoroughly ﬂush the...
Page 463 Lotus Service Notes 2-Eleven Fit M8 stud B111E6081S into RH top (as viewed on face) ﬁxing position in supercharger inlet ﬂange. Clean mating face on supercharger and inlet adaptor using Betaclean 3900. Fit 'O' ring into groove in adaptor face and ﬁt adaptor to supercharger using 2 off M8 x 30 ﬂange head bolts in top positions and M8 ﬂange nut on stud - all 25 Nm.
Page 464 Lotus Service Notes 2-Eleven Supercharger Nose Assembly If the supercharger input shaft oil seal should be damaged or found to leak, the complete nose assembly in- cluding the nose housing, shaft, bearings and seals should be replaced as a unit by the following procedure:...
Page 465 8x17, are ½ inch wider, front and rear, than the standard Exige wheels, but retain the standard insets of + 31.3 mm and + 38.0 mm. The wheels are ﬁnished in either Satin Black or High Power Silver, with 'Lotus Sport' moulded into one of the spokes of each wheel.
Page 466 Lotus Service Notes 2-Eleven Access to the brake master cylinder reservoir is available via a small panel in the driver's side front body; release the screw fastener using the tool provided in the roll over bar backstay, and withdraw the panel. To reﬁt, engage the tongue beneath the front end of the aperture, and secure the rear end with the fastener.
Page 467 Lotus Service Notes 2-Eleven Engine Bay Ventilation Engine bay cooling Chargecooler airﬂow The body of the 2-Eleven incorporates four air intake ducts; Grilled air intakes at each side of the front scuttle, feed air via ducting formed within the body sides to the engine bay; the left hand duct feeds a cool air supply with a small 'ram'effect to the engine air cleaner;...
Page 468 Lotus Service Notes 2-Eleven 2-ELEVEN.M - ELECTRICAL The 2-Eleven is available with three levels of lighting equipment: Track; with no lighting equipment. Race; with rear turn lamps, brake lamps and rear fog lamps. Road; with full lighting set, but no CHMSL.
Page 469 Press a second time to switch off the rain lamps. Lotus Traction Control All cars are equipped with Lotus Traction Control (LTC), whether or not the optional Limited Slip Differential (LSD) is speciﬁed. Lotus Traction Control (LTC) is a software programme within the engine electronic control unit (ECU) which uses inputs from the wheel speed sensors to determine the degree of wheelspin occurring, and when necessary, modulate fuel injector delivery to control engine power output until grip is restored.
Page 470 Lotus Service Notes 2-Eleven Variable Traction & Launch Control (if ﬁtted) Cars equipped with the optional variable traction and lauch control, have a rotary control knob mounted above the LTC ‘off’ button on the switch panel. Variable Traction Control Each time the ignition is turned on, normal full LTC is activated. To enable variable traction control, turn on the ignition and hold the LTC ‘off’...
Page 471 Lotus Service Notes 2-Eleven Battery Access The lightweight 'Odyssey' battery uses absorbed glass mat, dry cell technology to provide high electrical performance with minimum weight and size. The battery is located centrally in the cabin rear bulkhead, protected by a composite cover. No routine inspection or topping up of the electrolyte is required, but at every service in- terval, the battery terminals should be checked for security and condition, and protected with petroleum jelly.
Page 472 Lotus Service Notes 2-Eleven to be ‘jump’ started, the subsequent conditions of vehicle use may not allow for sufﬁcient alternator charging of the battery to achieve a fully charged state. The battery should be trickle charged by external means until 12.8 volts is recorded.
Page 473 Lotus Service Notes 2-Eleven Fuses Two 4-slot fuseboxes are mounted on the rear bulkhead and control the principal engine circuits. Track cars ﬁtted with rear lamps, use a third 4-slot fusebox, located within the battery compartment for the lighting circuits.
Page 474 U.K. Road Use Cars The following Warranty applies only to cars built by Lotus for road use in the U.K., as identiﬁed by V.I.N. character 12 being ‘F’ or ‘G’, and only whilst being used in the U.K. It is permissible for the car to be driven on closed circuits or private test tracks, but using the car in a competitive manner, including timed runs or laps, will invalidate the Lotus Vehicle Warranty.
Page 475 Lotus Service Notes 2-Eleven Circuit Diagrams Start, Alternator & Ignition Sheet 1 Page 28 Fuel Pump & Engine Management Sheet 2 Page 29 Engine Management Sheet 3 Page 30 Tail, Stop, Reverse & Fog Lamp Sheet 4 Page 31 Turn Indicators, Side & Hazard Warning Lamps...
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Lotus 2004 ELISE Service Notes

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