Lotus 2004 Eleven Service Notes
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Lotus 2004 Eleven Service Notes

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

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Summary of Contents for Lotus 2004 Eleven

  • Page 1 SERVICE NOTES 2004 Model Year Onwards with 1ZZ/2ZZ/1ZR Engine Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England. Tel: +44 (0)1953 608000 Fax: +44 (0)1953 608300 www.GroupLotus.co.uk...
  • Page 2 - Vehicle Chassis Bodycare & Repair Body Fittings Front Suspension Rear Suspension Engine & Engine Management - Lotus supplement - Toyota 1ZZ/2ZZ repair manual * see separate manual E120T0327J - Toyota 1ZR repair manual ** see separate CD T000T1523F Engine Management...
  • Page 3 Lotus Service Notes Introduction VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch area, viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside of the chassis sideframe alongside the driver's seat.
  • Page 4 Lotus Service Notes Introduction 2004 M.Y. - 2010 M.Y. serial no. 0359 Assembly Plant Model Vehicle Type H = Hethel 2 = 2-Eleven Manufacturer 111 = Elise/Exige Check B = Shah 3 = Elise Identifier Code 123 = 2-Eleven Digit...
  • Page 5 Lotus Sport Exige 240R: March 2005 Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the VIN coding.
  • Page 6 Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills, Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow door trims and unique black/yellow trimmed seats.
  • Page 7 Lotus Sport Exige Cup 255: January 2007 Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
  • Page 8 Donation to the Jim Clark memorial fund. Based on Elise SC with hard top and Sport Pack. BRG (B04) with Saffron single centre stripe, Lotus Sport wheels with black spokes and silver rims, A048 tyres. Black & red leather themed interior, with sports seats, wood gearknob and build plaque.
  • Page 9 Elise S model replaced by base Elise with 1.6 ltr. IZR FAE engine, featuring inlet and exhaust cam VVT-i, and VALVEMATIC inlet valve lift control, Lotus T6 controller; new 6-speed type EC60 transmission; revised rear subframe; optional cruise control.
  • Page 10 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 11 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 12 This publication has been designed for use by Lotus Dealers familiar with general workshop safety proce- dures and practices. Take all appropriate action to guard against injury to persons or damage to property. Lotus policy is one of continuous product improvement, and the right is reserved to alter specifications at any time without notice.
  • Page 13 - Vehicle Chassis Bodycare & Repair Body Fittings Front Suspension Rear Suspension Engine & Engine Management - Lotus supplement - Toyota 1ZZ/2ZZ repair manual * see separate manual E120T0327J - Toyota 1ZR repair manual ** see separate CD T000T1523F Engine Management...
  • Page 14 Lotus Service Notes Introduction VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch area, viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside of the chassis sideframe alongside the driver's seat.
  • Page 15 Lotus Service Notes Introduction 2004 M.Y. - 2010 M.Y. serial no. 0359 Assembly Plant Model Vehicle Type H = Hethel 2 = 2-Eleven Manufacturer 111 = Elise/Exige Check B = Shah 3 = Elise Identifier Code 123 = 2-Eleven Digit...
  • Page 16 Lotus Sport Exige 240R: March 2005 Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the VIN coding.
  • Page 17 Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills, Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow door trims and unique black/yellow trimmed seats.
  • Page 18 Lotus Sport Exige Cup 255: January 2007 Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
  • Page 19 Donation to the Jim Clark memorial fund. Based on Elise SC with hard top and Sport Pack. BRG (B04) with Saffron single centre stripe, Lotus Sport wheels with black spokes and silver rims, A048 tyres. Black & red leather themed interior, with sports seats, wood gearknob and build plaque.
  • Page 20 Elise S model replaced by base Elise with 1.6 ltr. IZR FAE engine, featuring inlet and exhaust cam VVT-i, and VALVEMATIC inlet valve lift control, Lotus T6 controller; new 6-speed type EC60 transmission; revised rear subframe; optional cruise control.
  • Page 21 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 22 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 23 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...
  • Page 24 Lotus Service Notes Section TDP GENERAL (for supercharged cars see section Exige S/C) Type designation - All nat. asp.except Elise S 2ZZ-GE - Elise S 1ZZ-FE - 2011 Elise 1ZR-FAE Configuration & no. of cylinders in-line 4 Capacity 1796 cm 1794 cm³...
  • Page 25 Lotus Service Notes Section TDP 2ZZ-GE 1ZZ-FE 1ZR-FAE CYLINDER BLOCK Material Aluminium alloy, Aluminium alloy, Aluminium alloy MMC bores cast iron liners cast iron liners Deck face flatness tolerance 0.05 mm Cylinder bore diameter (mm) 82.000 - 82.013 79.000 - 79.013 80.500 - 80.633...
  • Page 26 Lotus Service Notes Section TDP 2ZZ-GE 1ZZ-FE 1ZR-FAE Outer rotor to housing clearance - new 0.13 - 0.18 mm 0.12 - 0.19 mm - service limit 0.33 mm Inner rotor tip clearance - new 0.06 - 0.18 mm 0.08 - 0.16 mm - service limit 0.33 mm...

  • Page 27: Table Of Contents

    Lotus Service Notes Section TDQ TECHNICAL DATA - VEHICLE SECTION TDQ Page Dimensions ......................2 Capacities ......................3 Wheels & Tyres ....................3 Front Suspension ....................4 Rear Suspension ....................4 Electrical ......................5 Transmission ....................... 6 Clutch ........................6 Brakes .........................

  • Page 28: Dimensions

    Lotus Service Notes Section TDQ DIMENSIONS Overall length - Elise - pre 2011 3785 mm - 2011 on 3824 mm - Exige 3797 mm Overall width - exc. mirrors - Elise 1719 mm - Exige 1727 mm - inc. mirrors 1850 mm (approx.)

  • Page 29: Capacities

    Lotus Service Notes Section TDQ Trailer towing Not permissible CAPACITIES Engine oil - refill inc. filter - 2ZZ/1ZZ 4.4 litre (+ 3.5 litre if front mounted oil coolers are drained) - 1ZR 4.8 litre High/low dipstick mark difference - 2ZZ/1ZZ 1.5 litre...

  • Page 30: Front Suspension

    Lotus Service Notes Section TDQ FRONT SUSPENSION Type Independent. Upper and lower wishbone; co-axial coil spring/telescopic damper unit; anti-roll bar Steering axis inclination 12 ° nominal Geometry specification - Standard Elise: Mid-laden ride height (reference height for geometry check) - USA Elise from VIN 3013 & 111R/R/S...

  • Page 31: Electrical

    Lotus Service Notes Section TDQ Geometry specification - Elise option, Exige: Mid-laden ride height (reference height for geometry check) - front 130 mm below front end of chassis siderail - rear 130 mm below rear end of chassis siderail Camber - optimum - 1.8°...

  • Page 32: Transmission

    5-speed manual transaxle incl. final drive Differential - standard Open, bevel gear - option Torsen or plate type LSD combined with with Lotus Traction Control engine progamming Transmission designation - expt Elise S & '11 Elise C64 - Elise S...

  • Page 33: Brakes

    Lotus Service Notes Section TDQ BRAKES Brake discs Cast iron, curved vane ventilated, cross-drilled discs on all four wheels. Calipers - front A.P. Racing, aluminium alloy body, one pair of opposed pistons - rear Brembo, cast iron, single piston sliding rear calipers Disc size - front &...
  • Page 34 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...
  • Page 35 Lotus Service Notes Section AH Page 2...
  • Page 36 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 37 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 38 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 39 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 40 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...
  • Page 41 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 42 Do not follow other vehicles too closely in such circumstances. Washing Lotus recommends that the car be hand washed, using the following instructions: Many contaminants are water soluble and can be removed before any harm occurs by thorough washing with plenty of lukewarm water, together with a proprietary car wash additive (household detergent and washing up liquid can contain corrosive salts, and will remove wax and accelerate oxidation).
  • Page 43 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 44 & 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 45 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 46 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 con tainer with RED coloured cap.
  • Page 47 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 48 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 49 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 50 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 51 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 ob scured.
  • Page 52 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 53 Lotus Service Notes Section BQ Windscreen frame bonding (sills not shown) Windscreen frame Windsceen frame buttress Dash baffle panel Bonding path b281a Page 15...
  • Page 54 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 55 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 56 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 57 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 58 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 59 Section BR BR.1 - REMOVABLE ROOF The Lotus Elise has been designed to exploit the pleasures of open top motoring, the better to enjoy exposure to the natural environment, unencumbered by the restrictions and confinement bestowed by a cock- pit roof. In order to provide some weather protection to the occupants and vehicle interior, and allow the continued enjoyment of the car in unfavourable weather conditions, a simple hard or soft top roof may be fitted.
  • Page 60 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 61 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 62 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 63 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 64 Lotus Service Notes Section BR BR.3 - FRONT BODY ACCESS PANELS Elise Two removeable, body colour compos- ite panels are provided in the front body to allow access to the front fusebox and brake fluid reservoir. To remove an access panel: Use the hexago-...
  • Page 65 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 66 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 67 Lotus Service Notes Section BR Clamshell spine to Fixing inside wiper motor bracket headlamp housing Clamshell lower front Fixing to edge to undertray windscreen frame Fixing to base of windscreen pillar Fixing to radiator mounting panel (not used with oil coolers)
  • Page 68 Lotus Service Notes Section BR BR.7 - REAR CLAMSHELL The rear clamshell is a one piece composite moulding incorporating both rear wings, the engine bay aperture, rear transom and integral luggage bay. The clamshell is secured to the chassis and other body panels by threaded fasteners for ease of service access and body repair.
  • Page 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 89 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 90 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 91 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 92 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 93 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 94 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 95 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 96 Lotus Service Notes Section CI CI.1 - GENERAL DESCRIPTION The fully independent front suspension comprises, on each side of the car, upper and lower wishbones, a concentric coil spring/telescopic damper unit, and a tubular anti-roll bar. A forged steel hub carrier, provides a mounting for a the hub bearing unit to which the road wheel is attached via four spline socket bolts.
  • Page 97 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 98 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 allied to a particular wheel/tyre combination.
  • Page 99 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 100 Lotus Service Notes Section CI Notes Shim distribution at the front bush of either wishbone must be copied at the rear bush of that wishbone. Transferring a 1.5mm shim washer from ahead of, to behind the pivot bushes, will reduce castor by ap- proximately 0.4°.
  • Page 101 Lotus Service Notes Section CI These hard type mountings provide optimum steering response but will transmit more noise and require periodic lubrication with MoS grease at 3,000 mile (5,000 km) intervals. Noise from excessive clearance may be ameliorated by judicious shaving of the clamping block faces.
  • Page 102 Lotus Service Notes Section CI CI.4 - 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, and a spring compressor, required only if the spring is to be removed from the damper unit.
  • Page 103 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 104 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 105 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 106 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 107 Lotus Service Notes Section DH DH.1 - GENERAL DESCRIPTION The fully independent rear suspension comprises, on each side of the car, upper and lower tubular steel wishbones, a toe control link, and a concentric coil spring/telescopic damper unit linked between the outboard end of the lower wishbone and the chassis.
  • Page 108 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 109 Permabond A130 (A912E7033) to the threads, and torque tighten to the appropriate figure. Retrofitment of the later type bolts is recommended. Any attempt to adjust camber outside of Lotus specification, may result in inappropriate bolt thread en- gagement, and endanger security.
  • Page 110 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 111 Lotus Service Notes Section DH 11. Remove the heatshield over the toe-link inboard ball joint, release the toe-link stud, remove the lower wishbone front pivot bolt and withdraw the lower wishbone and toe link. 12. If necessary, remove the top swivel joint ball pin nut, and use a ball joint splitter tool to separate the joint from its plinth.
  • Page 112 Lotus Service Notes Section DH Top ball joint plinth fixing bolts: The bolts securing the top ball joint plinth to the hub carrier were upgraded in March '04 at VIN serial number 1537 (approx.) in order to commonise with motorsport applications. Earlier type 8.8 grade bolts should be tightened to 45 Nm;...
  • Page 113 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 114 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 115 Lotus Service Notes Section DH DH.5 - TRACK USE CHASSIS REAR BRACE KIT - LOTAC05377 The purpose of the kit is to provide a 'double shear' mounting for the inboard ends of the rear toe-links and spread the load distribution into the chassis over a wider base. New spherical joints are used on the inboard ends of the toe-links, with a tubular steel crossbrace interconnecting the two pivot bolts and anchoring to the rear engine steady mounting on the subframe.
  • Page 116 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 117 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 118 Lotus Service Notes 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 119 6.5J. Insets are unchanged. Yokohama A048 Tyres The Yokohama A048 tyres have been developed jointly by Lotus and Yokohama to suit the requirements of the performance driver, with special emphasis on track use. Compared with the standard tyre, the front tyre width is increased and the profile reduced from 175/55 to 195/50.
  • Page 120 Lotus Service Notes Section DH Alignment - optimum Zero - tolerance range 0.5 mm toe out, to 0.7mm toe-in overall Rear Mid-laden ride height (reference height for geometry check) - front 120 mm below front end of chassis siderail - rear...
  • Page 121 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 122 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 necessary clearance.
  • Page 123 Tyre pressures are unchanged. The Lotus specific construction is identified by the letters 'LTS' moulded on the tyre sidewall. Ensure that any replacement tyre is so marked.
  • Page 124 Lotus Service Notes Section EH ENGINE SECTION EH Sub-Section Page General Description; 2ZZ-GE EH.1 General Description; 1ZZ-FE EH.2 Maintenance Operations; 2ZZ & 1ZZ EH.3 Engine Removal/Replacement EH.4 Special Tools EH.5 Engine Management Component Location EH.6 2010 Elise 1ZR FAE Supplement EH.7...
  • Page 125 Lotus Service Notes Section EH Engine Sections (2ZZ-GE) From LH side From front e226 Cylinder Head Section Exhaust side Inlet side e227 Page 2...
  • Page 126 EH.1 - GENERAL DESCRIPTION; 2ZZ-GE 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 127 Lotus Service Notes Section EH e223 e222 e224 Page 4...
  • Page 128 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 129 Lotus Service Notes Section EH e225 Page 6...
  • Page 130 Lotus Service Notes Section EH Airbox Flap Valve In order to reduce airflow restriction into the airbox at periods of high demand, and also to provide an acoustic enhancement, the ECU, when switching to high valve lift mode, also opens a flap valve in the under- side of the airbox body.
  • Page 131 Knock Sensor (2ZZ only) The knock sensor used for Lotus applications is an annular type fitted over an M8 stud, with the retaining nut tightened to 20 Nm. Note that the 1ZZ engine does not use a knock sensor.
  • Page 132 Lotus Service Notes Section EH EH.2 - GENERAL DESCRIPTION; 1ZZ-FE 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 133 Lotus Service Notes Section EH EH.3 - MAINTENANCE OPERATIONS - 2ZZ & 1ZZ Engine Oil Level Check The engine oil level should be checked regularly, such as every two or three fuel stops, and the oil level maintained near the top mark on the dipstick. It is especially important to keep a check on the oil level during the vehicle’s first 1,000 miles (1,600 km), as both the fuel and oil consumption will be prone to some variance...
  • Page 134 Remove the filter by turning in a counterclock- wise direction, if necessary using an oil filter OIL FILTER wrench, and dispose of safely. (Viewed Ensure that only a Lotus specified filter is from fitted, as parts with identical outward appear- beneath) ance can contain different internal features.
  • Page 135 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 contamination, more frequent replacement will be required dependent on the level of pollution.
  • Page 136 Lotus Service Notes Section EH EH.4 - 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 137 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 138 For coolant refilling procedure, refer to section KH. For transmission details and gear cable adjustment, refer to section FJ. EH.5 - SPECIAL TOOLS The following engine special tools are available under Lotus part number: Engine Lift Bracket T000T1437S 2 off...
  • Page 139 Lotus Service Notes Section EH EH.6 - ENGINE MANAGEMENT COMPONENT LOCATION - 2ZZ 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.
  • Page 140 The 1.6 litre Elise announced. in January 2010 replaces the 1.8 litre Elise S model, and uses the Toyota 1ZR FAE engine, but controlled by a type T6 Lotus ECU (also used on Evora), programmed by Lotus. This D HC 16 va v n line...
  • Page 141 6.14 litres/100 km (46 mpg). Exhaust emissions CO 155 g/km Engine management: Lotus T6 controller (as Evora) with Lotus programming. Valve control: VVT-i variable timing of both inlet and exhaust cams; VALVEMATIC variable lift system for the inlet valves. Engine speed control: Intake plenum throttling at low engine speeds;...
  • Page 142 Lotus Service Notes Section EH VALVEMATIC System The principle of the VALVEMATIC system is that a conventional inlet camshaft with a single (rotary) cam for each cylinder operates a roller arm on a pivot shaft. On each side of the roller arm is an oscillating cam, each of which opens, via a finger follower, one of two conventional inlet valves for that cylinder.
  • Page 143 Lotus Service Notes Section EH Auxiliary Belt Tension The auxiliary belt tension on the 1ZR FAE engine is set manually by adjusting the alternator position. An adjusting screw for this purpose is provided on the alternator strap, and may be utilised after slackening the strap anchor and clamp bolts, and the alternator lower pivot bolt.
  • Page 144 Lotus Service Notes Section EMP ENGINE MANAGEMENT SECTION EMP Sub-Section Page Diagnostic Trouble Code List EMP.1 Diagnostic Scanner Tools 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 145 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 146 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 147 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 148 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 149 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) • MAF sensor ground open circuit (MAF value (g/sec) > 229.0) Notes: • The MIL will be illuminated if the faults are present for 2 consecutive trips • Further information on the sensor may be found in Toyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J) Page DI-26 to DI-32 Page 6...
  • Page 150 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 151 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 152 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 • Further information on the sensor may be found inToyota 1ZZ-FE, 2ZZ-GE manual RM733E (B120T0327J) pages DI-33 to DI-38 Page 9...
  • Page 153 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 154 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...
  • Page 155 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 156 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 P0123 Enable Criteria: None Disable Criteria: P0016 – Crankshaft/Camshaft position correlation error Potential failure modes: • Signal open circuit (> 4.487 V)
  • Page 157 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 158 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 159 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 160 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) pages DI-53 to DI-62 Page 17...
  • Page 161 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 162 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.; Set when sensor fails to switch between 250mV and 650mV with sufficient rapidity).
  • Page 163 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 164 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 165 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 166 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...
  • Page 167 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 168 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’ are positioned at 225 degrees before cylinder No.1 and 4 TDC. The crankshaft sensor signal is also used to determine misfires events.
  • Page 169 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° apart, which are detected by the electromagnetic sensor. The valve timing setting is measured in the ECU by measuring time from a (fixed position) crankshaft tooth to a (variable position) camshaft tooth.
  • Page 170 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 171 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 172 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 173 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 174 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 175 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 176 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. in brackets 3 (ACCM 2*) Relay #2...
  • Page 177 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 178 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 179 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 Disable Criteria: None Potential failure modes: • Alternator fault • Battery fault Notes: The MIL will be illuminated if the fault is present for 2 consecutive trips.
  • Page 180 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 181 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 182 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. in brackets *ACCM – A/C Control Module...
  • Page 183 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 184 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 185 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 186 Lotus Service Notes Section EMP EMP.2 - DIAGNOSTIC SCANNER TOOLS In order to provide for communication with the engine management system electronic control module, a hand held electronic scanner ‘Lotus Scan’ (part number T000T1418F), may be plugged into a special 16 terminal harness connector socket, known as a Data Link Connector (DLC), located at the front of the passenger footwell.
  • Page 187 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 188 Note that this laptop should be dedicated soley to the Lotus TechCentre, with no other software installed. This diagnostic software is designed primarily for use by trained Lotus technicians, and is available as a CD under part number T000T1510F (version 4) or later supercessions. A monthly (Lotus Dealers) or annual (non- Lotus dealers) licence and support fee will also be levied, providing access to Lotus TechCentre Technical Support phoneline on 0870 9493 668, and e-mail on lotus.support.uk@omitec.com...
  • Page 189 Lotus Service Notes Section EMP Page 46...
  • Page 190 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 191 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 192 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 193 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 194 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 195 Lotus Service Notes Section EMP 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 Potential failure modes: # VIN not programmed...
  • Page 196 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 P2102 Monitor: Continuous...
  • Page 197 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 198 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 199 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 200 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 201 Lotus Service Notes Section EMP EMP.7 - DIAGNOSTIC CODE SUPPLEMENT - 2011 M.Y. ELISE (Euro 5) Fault Description Page P0011 A Camshaft Position - Timing Over-Advanced or System Performance P0012 A Camshaft Position - Timing Over-Retarded P0014 B Camshaft Position - Timing Over-Advanced or System Performance...
  • Page 202 Lotus Service Notes Section EMP Fault Description Page P0341 Camshaft Position Sensor “A” Circuit Range/Performance 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 P0366 Camshaft Position Sensor “B”...
  • Page 203 Re-instatement of the power supply will not automatically eradicate the code, and neither will clearing of the code via Lotus TechCentre be effective until a learing process has been completed. After rectification of the power supply fault, proceed as follows: Ignition off and allow ECU to power down (wait for 30 seconds).
  • Page 204 Lotus Service Notes Section EMP Page 61...
  • Page 205 Lotus Service Notes Section EMP Page 62...
  • Page 206 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: 1ZZ / 2ZZ - C64/C56 repair manual E120T0327J...
  • Page 207 Lotus Service Notes Section FJ FJ.1 - INTRODUCTION The Elise S 5-speed transmission, the 2ZZ powered Elise/Exige 6-speed transmission, and the 1ZR powered Elise 6-speed, are all of similar construction, being 'end on' type, mounted on the left hand end of the engine unit, and comprising the clutch housing, gearbox, final drive gears, and differential.
  • Page 208 Lotus Service Notes Section FJ C64 Six Speed (reverse idler omitted for clarity) Input shaft Output shaft Clutch/Diff housing End cover Gearbox Centre support casing bearing f145 EC60 Six Speed Reverse idler Input shaft Output shaft Clutch/Diff housing Gearbox casing...
  • Page 209 Lotus Service Notes Section FJ The two shaft, all indirect gearbox, is housed within a two or three part cast alloy casing, including the dry chamber clutch housing, and secured by threaded fasteners to the back of the engine block. The clutch friction plate is splined to the gearbox input shaft from which the power flows to the output shaft mounted below it, and thence to the final drive and differential into which are fitted the driveshafts.
  • Page 210 Lotus Service Notes Section FJ C64 Gear Clusters (other variants similar) 6th gear 5th gear 4th gear 3rd gear 2nd gear 1st gear Reverse Input shaft f130 Output shaft Double cone 2nd Final drive gear gear synchromesh The input shaft includes integral drive pinions for 1st, 2nd and reverse gears, and carries the clutch driven plate, the 3rd/4th synchroniser and the 5th/6th synchroniser.
  • Page 211 Optional on some C64 equipped models, in conjunction with electronic Lotus Traction Control (LTC), is a Torsen type limited slip differential (LSD) in an otherwise unchanged transmission housing (Character 3 of 7 digit code on bar code label: 'O' = open; 'L' = LSD).
  • Page 212 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 213 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 214 Lotus Service Notes Section FJ the aperture and re-adjust the crossgate cable as necessary. If other adjustments have been made, check the alignment of the 3rd/4th lever plane. From the spring loaded neutral position, it should be possible to smoothly engage 3rd and 4th gears without moving the lever across the gate.
  • Page 215 Lotus Service Notes Section FJ Page 10...
  • Page 216 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 217 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 218 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 219 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 220 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 will certainly be evident.
  • Page 221 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 222 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 223 Lotus Service Notes Section FJ Clutch housing to engine fixings - viewed from gearbox side (2ZZ shown) M12x55 flange head bolts to block; 64 Nm M10x65 bolts also secure M10x55 bolts to starter motor; 37 Nm block; 37 Nm f134 M10x30 bolts to sump; 23 Nm FJ.6 - TRANSMISSION OVERHAUL The overhauling of the Toyota supplied type C64/C56 transmission, is detailed in separate publication E120T0327J.
  • Page 224 The transmission cross-shaft reverse select compression spring shown in the Toyota Repair Manual is removed for the Lotus application. When fitting a replacement transmission, compare the cross shaft spring loading of the old and new units to determine whether this modification has been carried out.
  • Page 225 Lotus Service Notes Section FJ Torque wrench f143 For cars fitted with a limited slip differential, note the following: Apart from the taper roller bearings supporting the differential assembly in the transmission case, the unit is not serviceable. The tightening torque of the bolts securing the final drive gear to the differential assembly = 101 Nm (Std.
  • Page 226 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 227 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 228 Lotus Service Notes Section GH Type - Std. - Elise Rimstock, cast alloy, 8 spoke, Hi-power Silver - Exige Rimstock, cast alloy, 8 Y-spoke, Black ) see parts list - Option Rimstock, lightweight forged alloy, 7 split-spoke, ) for details Silver painted or natural anodised finish.
  • Page 229 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 230 The tyres are NOT suitable for studding. Snow Chains In extreme conditions, Lotus approves the fitment of Pewag Brenta-C XMR69 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 as road conditions allow.
  • Page 231 Lotus Service Notes Section GH GH.5 - PUNCTURED TYRE EMERGENCY INFLATOR (IF FITTED) 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 232 Lotus Service Notes Section GH 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 233 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 234 Lotus Service Notes Section HG General Layout Upper column Upper column assembly mountings Track rod Intermediate column Lower Upper u/j Rack mounting plinth Thrust pad adjuster Rack housing Gaiter Track rod HG.1 - GENERAl DESCRIPTION The steering system of the Elise comprises a telescopically collapsible upper column assembly, connecting to a rigidly mounted rack and pinion assembly via a universally jointed intermediate shaft.
  • Page 235 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) Pull off the centre trim pad with horn but- ton, and disconnect the two horn leads.
  • Page 236 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 237 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 238 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 239 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 ± 1mm...
  • Page 240 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. Precau- tions need to be taken for personal safety when working with airbags and associated componentry. Do not attempt to remove the airbag, steering wheel or column without first referring to section WD.
  • Page 241 Lotus Service Notes Section HG Airbag Type Instrument pack Instrument cowl Instrument mounting bracket fixings (4 off) Upper column clamp fixings b343 11. 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 242 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 243 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 244 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 245 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 246 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 Scanner Tool Checking Procedures JJ.17 Page 1...
  • Page 247 Lotus Service Notes Section JJ Page 2...
  • Page 248 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 249 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 250 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 251 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 252 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 253 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 254 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 255 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 256 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 257 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 258 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 259 Lotus Service Notes Section JJ The new callipers do not require the thicker disc bells formerly used to provide wheel/calliper clearance, or the corresponding increased length wheelbolts. Consequently, a new version of the two piece disc assembly uses the standard 8 mm flange thickness and standard wheelbolts.
  • Page 260 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 261 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 262 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 263 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 264 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 265 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 266 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 267 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 268 Lotus Service Notes Section JJ FROM '06 M.Y. Introduced for the 2006 model year, was electronic throttle control (ETC), which dispensed with the me- chanical 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 269 Lotus Service Notes Section JJ JJ.12 - ABS THEORY OF OPERATION 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 270 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 271 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 272 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 273 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 274 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 275 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 276 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 277 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 278 In order to provide for communication with the engine management system electronic control module, a hand held electronic scanner 'Lotus Scan' (part number T000T1418F), may be plugged into a special 16 terminal harness connector socket, known as a Data Link Connector (DLC), located at the front of the passen- ger footwell.
  • Page 279 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 280 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.
  • Page 281 Lotus Service Notes Section JJ TechCentre Connection TechCentre connection to the car is made via the Vehicle Communication Device (VCD) and the Data Link Connector (DLC) located at the front of the passenger footwell. The yellow connector lead is used to connect the VCD to the car, and a USB lead connects the VCD to the laptop PC.
  • Page 282 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 283 Lotus Service Notes Section JJ Abbreviations & Definitions BATTERY VOLTAGE System voltage BRAKE LIGHT SW. Brake light switch FL WHEEL SPEED Front left wheel speed FR WHEEL SPEED Front right wheel speed RL WHEEL SPEED Rear right wheel speed RR WHEEL SPEED...
  • Page 284 Lotus Service Notes Section JJ Circuit Diagram Diagnostic Trouble Codes Page 39...
  • Page 285 C-02 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 40...
  • Page 286 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 287 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 288 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 289 Lotus Service Notes Section KH level of coolant will rise as the engine warms up and the coolant expands, and will fall again as it cools down. WARNING: Do NOT remove the cap or bleed plug from the engine cooling header tank when the engine is warm, as serious scalding could result from boiling water and/or steam.
  • Page 290 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 291 Lotus Service Notes Section KH Radiator Mounting Rear mounting Front mounting spreader plate spreader plate Radiator mounting panel Front Access to this mounting clip available bracket via turn lamp aperture Rear mounting bracket Engine cooling radiator Air conditioning condenser Fan fixing...
  • Page 292 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 293 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 294 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 295 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 296 Lotus Service Notes Section LJ FUEL SYSTEM SECTION LJ - ELISE 111R, EXIGE 2004 M.Y. On (non USA) Sub-Section Page General Description LJ.1 Fuel Filling LJ.2 Precautions LJ.3 Fuel Tank LJ.4 Fuel Pump/Sender Assembly LJ.5 Charcoal Canister LJ.6 Page 1...
  • Page 297 Lotus Service Notes Section LJ Page 2...
  • Page 298 Lotus Service Notes Section LJ LJ.1 - GENERAL DESCRIPTION The 43.5 litre fuel tank is fabricated from Neotec coated steel, and is externally powder coated for further corrosion resistance. The tank is mounted within the chassis crossmember between the passenger compart- ment and engine bay, and is secured by two support brackets from beneath.
  • Page 299 Lotus Service Notes Section LJ To unlock the cap, insert the key (same key as ignition), turn ¼ counterclockwise and withdraw the cap with the key. As the cap is unlocked, any slight pressure differential between the tank and atmosphere will be released, and a brief hiss may be heard, which is completely normal.
  • Page 300 Lotus Service Notes Section LJ Fuel pipe to Orange engine safety lock Before re-making the joint, ensure that the or- ange safety lock is fitted onto the pipe connec- Fuel pipe tor in the orientation shown in the illustration. from tank Push the male pipe end fully into the female connector until a click is heard.
  • Page 301 Lotus Service Notes Section LJ Disconnect control cables: Release the two gearchange cables from the transmission levers and abutment bracket. Release the parking brake cable from the horseshoe compensator and abutment brackets. Release the throttle cable from the engine. Release the gearchange cable and throttle cable 'P' clips from the perforated 'shear panel' below the fuel tank.
  • Page 302 Lotus Service Notes Section LJ Polypropylene saddles Fuel tank Foam sponge Rubber wedge Earth braid Support cradle L59b Ensure the pump/sender unit is fitted into the into the tank, with the earth braid fitted onto the '10 O'clock' position pump mounting stud.
  • Page 303 Lotus Service Notes Section LJ To Remove Pump/sender Assembly Remove the fuel tank (see sub-section LJ.4). Release the eight nuts securing the clamping ring, and carefully withdraw the pump assembly from the tank. Immediately seal the tank aperture to reduce the fire hazard and prevent dirt ingress.
  • Page 304 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 305 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. • 'Dynamic coding' of the transmitter keys; Each time the transmitters are used, the encrypted rolling code is changed to guard against unauthorised code capture.
  • Page 306 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 307 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 308 Lotus Service Notes Section MP Enter the PIN: Immediately the tell tale goes out, switch ON the ignition and count the number of security tell tale flashes until equal to the first number of the PIN, then turn the ignition OFF, then back ON again.
  • Page 309 Lotus Service Notes Section MP MP.2 - CENTRAL DOOR LOCKING (IF FITTED) The central door locking (CDL) operates on the driver’s and passenger’s doors in conjunction with the security alarm system, which includes CDL circuitry in the Cobra 8186 alarm controller. To lock the car, remove the ignition key, close both doors and check that the engine cover and front body access panels are secure.
  • Page 310 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’ button which glows amber when the lights are switched on.
  • Page 311 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. I - 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 312 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 313 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 314 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 315 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 switching on the ignition, and then the headlamps. A tell tale in the switch button lights up amber to indicate when the circuit is active.
  • Page 316 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 317 Lotus Service Notes Section MP Lens rocked upwards; lamp is switched off. NOTE: On USA cars, arming the alarm with the interior lamp switched off may exclude the doors from activating the alarm. Lens central; lamp is switched on, with or without ignition. Lens rocked downwards; a courtesy mode applies, where the lamp is switched on whenever a door is opened, and goes out when the doors are closed. In addition, the alarm disarm command will also light the interior lamp for a period of 30 seconds, or until the ignition is switched on.
  • Page 318 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 319 Lotus Service Notes Section MP Component Location CDL module Engine bay fuseboxes Horn mounted on crash structure mounting plate Fusebox Inertia switch Radiator fan/a.c. control module Fuse block fuse Switch Horn relay pl1703mt controller CDL trip relay Flasher unit Wiper delay MP.6 - AUDIO EQUIPMENT...
  • Page 320 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 321 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 322 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 323 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 324 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; one running forwards across the front of the chassis well to feed...
  • Page 325 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 326 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 327 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 328 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 329 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 14 20A Rad. fans;...
  • Page 330 Lotus Service Notes Section MP Interior Fuses & Relays Front Fuseboxes ‘C’ The wash/wipe module, turn/hazard flasher relay, horn relay and a relay for inertia  switch activation of the central door locking, are mounted on the scuttle beam above the passenger footwell, with two 4-slot fuse holders secured to the harness in that area.
  • Page 331 Replacement Keys: Additional or replacement transmitter keys may be purchased uncut/uncoded from Lotus under part number A120H0008S and will be supplied with a blank mechanical blade for copy cutting to an existing key. Alternatively, a cut key may be ordered from Bolton Lock Company, quoting the 4 digit ‘L’ key code, under...
  • Page 332 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. With the ignition off, the alarm tell tale will indicate that immobilisation is in effect by briefly flashing every second.
  • Page 333 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 334 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 335 Lotus Service Notes Section MP Component Location The location of the PFK alarm components is unchanged from the equivalent earlier Cobra parts; the controller is mounted on top of the scuttle beam at the LH extreme end. Access requires removal of the fascia top. The immobiliser is incorporated into the controller as a single unit. The siren is mounted on the front of the radiator duct LH extension, beneath the LHF turn lamp.
  • Page 336 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 337 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 338 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. The Vehicle Communication Device (T000T1472F) introduced for the Europa model is used to connect the vehicle to the laptop Lotus TechCentre.
  • Page 339 Lotus Service Notes Section MP MP.13 - 2011 M.Y. SUPPLEMENT Cruise Control - optional fitment on 1.6 ltr Elise; not available on other models. Caution: Cruise control should be used only when conditions are favourable; on straight, dry, open roads with light traffic. The cruise control system is incorporated into the engine ECU programme, and allows the maintenance of a selected vehicle speed above 30 mph (50 km/h), without having to use the accelerator pedal. The tell tale lamp in the gear lever shroud is lit whenever cruise control is active.
  • Page 340 Lotus Service Notes Section MP Daytime Running Lamps (DRL) - Elise The 2011 Elise is fitted with headlamp assemblies incorporating amber LED string turn indicators, and dual intensity white LED string parking/daytime running lamps. 1.8 litre cars: When the ignition is turned on, the front and rear sidelamps will automatically be activated as daytime running lamps.
  • Page 341 Lotus Service Notes Section MP Engine Compartment Fuses Fuses associated with the engine management system are contained in two 4-position fuse holders lo- cated 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 376 Lotus Service Notes Section MP.14e ELECTRICS SECTION MR.14e CIRCUIT DIAGRAMS 2011MY ELISE WITH 1ZR POWERTRAIN Contents List Circuit Diagrams Circuit Diagrams 3 - 47 Fuse Layout Colour Codes & Abbreviations Page 1 Updated 19th May 2010...
  • Page 377 Lotus Service Notes Section MP.14e MP.14e - CIRCUIT DIAGRAMS Circuit Sheet Page Battery Supply Accessory Key In Accessory Supply Ignition Supply Charging System CAN Network Diagnostic Link Connector Grounding Structure Cranking Alarm & Immobiliser Central Locking EMS Power & Ground...
  • Page 378 Lotus Service Notes - 2011MY Elise Circuit Diagrams - All Markets Section MP.14e 1ZR Powertrain Page 3...
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  • Page 401 Lotus Service Notes - 2011MY Elise Circuit Diagrams - Non USA Section MP.14e 1ZR Powertrain Page 26...
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  • Page 425 Lotus Service Notes Section MP.14e Colour Code B = Black P = Purple R = Red S = Slate (Grey) U = Blue W = White Y = Yellow G = Green K = Pink LG = Light Green N = Brown O = Orange...
  • Page 426 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...
  • Page 427 Lotus Service Notes Section OI RECOMMENDED LUBRICANTS Engine In order to ensure the longevity and reliability of the vehicle, it is most important that only the specified lubricants are used. It is an entirely false economy to try to save money by using lower quality oils, which may break down before the next change interval and provide inadequate protection before the end of the term.
  • Page 428 However, use of the car in a competitive manner, including timed runs or laps, is not endorsed by Lotus. This type of timed, competitive use will invalidate warranty and require appropriate levels of expert vehicle preparation and servicing over and above that specified in the Maintenance Schedule.
  • Page 429 If applicable: Check Accusump pressure/operation and system for leaks. Renew in-line filter gauze 10 Inspect integrity of fuel system 11 Connect 'Lotus TechCentre'; inspect fault codes & ECU programme le 12 Print Engine History & Performance data and return to Lotus Cooling System Inspect water radiator &...
  • Page 430 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 431 4. Thorough safety check including wheels, tyres, suspension, steering and brake systems. 5. The Lotus Elise/Exige is designed as a road going sports car. It is recognised that owners may wish to use the car occasionally on closed circuit tracks to experience the car's full range of dynamic capabilities. However, use of the car in a competitive manner, including timed runs or laps, is not endorsed by Lotus.
  • Page 432 10 Inspect integrity of fuel system 11 Connect 'Lotus TechCentre'; inspect fault codes & ECU programme 12 Print Engine History & Performance data and return to Lotus Cooling System Inspect water radiator & oil cooler hoses & pipework for damage or leaks.
  • Page 433 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 434 Check presence of vehicle handbook, audio booklet & other documentation. Complete pages 2, 3, 4a & 4c in "Maintenance Record" booklet. Cut out pages 4a & 4c for return to Lotus Cars Warranty Department. Copy alarm installation certificate, PIN & key details (inc. locking wheel bolts). Originals to customer.
  • Page 435 All costs incurred during the inspection process are the res- ponsibility of the dealer. c) Failure to return a signed copy of this inspection to Lotus Cars Ltd. by the dealer, may result in warranty claims on the particular car being rejected.
  • Page 436 Lotus Service Notes Section OI PRE-DELIVERY PAINT MARK UP - ELISE 2 lsl407a PAINT DEFECT CODE B BLISTERING N SHADING C CHIPS O OVERSPRAY COLOUR D DISTORTION P PRE-RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES OWNER H PIN HOLES...
  • Page 437 Lotus Service Notes Section OI PRE-DELIVERY PAINT MARK UP - EXIGE lsl409a PAINT DEFECT CODE B BLISTERING N SHADING C CHIPS O OVERSPRAY COLOUR D DISTORTION P PRE-RELEASES F FLAKING R RUN G GEL CRAZING S SCRATCHES OWNER H PIN HOLES...
  • Page 438 Lotus Service Notes Section OI Licence Plate Fitment - Except North America Front The mounting plinth for the front licence plate is moulded into the front clamshell, and is slightly curved in plan. Typically, double sided tape in conjunction with two fixing screws are used to secure the plate which should not project above the top edge of the plinth by more than 40mm, or cooling performance will be inhibited.
  • Page 439 Section OI Page 14...

  • Page 440: Updated 9Th June

    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 441 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 442 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 443 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 444 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 445 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 446 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 447 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 448 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 449 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 450 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 451 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 452 Lotus Service Notes Section PL PL.4 - REFRIGERANT HANDLING The system is charged with 0.55 kg of refrigerant HFC R134a, and the following precautions MUST ALWAYS BE OBSERVED. On no account should refrigerant ever be discharged to atmosphere - use a refrigerant recovery/recycling station in accordance with the manufacturer's instructions.
  • Page 453 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 454 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 455 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 456 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 457 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 458 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 459 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 460 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 461 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 462: Bq.1

    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 463 Lotus Service Notes Section PL Hot air dam Gutter extension panel Radiator inboard fixing sb79 Page 24...
  • Page 464 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 Supplement for 2011 Elise QH.5 Page 1 Updated 9th June 2010 Updated 9th June 2010...
  • Page 465 Lotus Service Notes Section QH Page 2 Updated 9th June 2010...
  • Page 466 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 467 Lotus Service Notes Section QH Pedal box Connection to fluid reservoir Clutch master cylinder Mounting bolt Pedal pushrod Clutch pipe connector Slave Cylinder 2ZZ & 1ZR Powertrain 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 468 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 469 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 2ZZ & 1ZR POWERTRAIN The clutch assembly comprises the friction plate, clutch cover assembly (pressure plate/diaphragm spring/cover) and release bearing.
  • Page 470 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 cal- lipers, measure the depth of the rivet heads below the surface of the friction material.
  • Page 471 Lotus Service Notes Section QH Clutch housing to engine fixings - viewed from gearbox side (2ZZ shown) M12x55 flange head bolts to block; 64 Nm M10x65 bolts also secure M10x55 bolts to starter motor; 37 Nm block; 37 Nm f134 M10x30 bolts to sump;...
  • Page 472 Lotus Service Notes Section QH QH.5 - SUPPLEMENT FOR 2011 ELISE - 1ZR POWERTRAIN The 2011 model Elise is fitted with a conventional single dry plate clutch with diaphragm spring cover, but the 1ZR powertrain uses a concentric type clutch release slave cylinder mounted inside the clutch housing and surrounding the transmission input shaft.
  • Page 473 Lotus Service Notes Section WD AIRBAG SYSTEM SECTION WD - ELISE/EXIGE Sub-Section Page General Description WD.1 Airbag Tell Tale WD.2 Data Link Connector WD.3 Trouble Codes WD.4 Diagnostic Scanner Tools WD.5 Safety Precautions, Shipping, Storage & Disposal WD.6 Theory of Operation WD.7...
  • Page 474 Section WD WD.1 - GENERAL DESCRIPTION The airbag Supplementary Restraint System (SRS) was introduced on the Lotus Elise for USA markets, first produced for 2005 model year. This was then offered as an option for other LHD markets, and later for RHD.
  • Page 475 In order to provide for communication with the airbag SDM, engine management system ECU and anti- lock brake system, a hand held electronic scanner 'Lotus Scan 3' (part number T000T1418F), may be plugged into the Data Link Connector (see earlier)
  • Page 476 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 477 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.
  • Page 478 Lotus Service Notes Section WD TechCentre Connection TechCentre connection to the car is made via the Vehicle Communication Device (VCD) and the Data Link Connector (DLC) located at the front of the passenger footwell. The yellow connector lead is used to connect the VCD to the car, and a USB lead connects the VCD to the laptop PC.
  • Page 479 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 480 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 481 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 482 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. If the SRS was deployed, the following components MUST be renewed even if there is no visible damage to the parts: Driver airbag module;...
  • Page 483 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 484 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 485 Use Scan 3 tool or Lotus TechCentre to configure airbag system. WD.9 - DRIVER AIRBAG MODULE WARNING: Safety precautions must be observed when handling a deployed airbag.
  • Page 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494 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 495 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 496 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 497 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 498 Lotus Service Notes Exige S/C Page 6...
  • Page 499 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 500 Other 240 and upwards versions, and all USA cars, use 4 special high-flow port 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 modulated between 4,500...
  • Page 501 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 Routine Checks Be aware that the indicated oil level on the dipstick will depend on the amount of oil stored in the Accu- sump, which itself is dependent on the both the Accusump pre-charge air pressure and the engine oil pressure when the ignition was switched off.
  • Page 502 Lotus Service Notes Exige S/C Continue to idle the engine until normal running temperature is reached, then check the level on the dipstick (with 40 psi showing on the Accusump gauge) as detailed above. Top up the oil to the top mark on the dipstick.
  • Page 503 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 504 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 505 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 506 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 507 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 508 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 509 Lotus Service Notes 2-Eleven 2-ELEVEN.A - CHASSIS The 2-Eleven uses the basic chassis 'tub' of the Elise/Exige with minor revisions including; Deletion of door hinge upright extrusions on each end of scuttle beam. Full height side members (no cabin access cut down).
  • Page 510 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 511 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 512 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 513 Lotus Service Notes 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 514 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 515 Lotus Service Notes 2-Eleven 2-ELEVEN.E - ENGINE 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.
  • Page 516 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 517 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 518 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 519 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 520 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 521 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 522 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 523 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 524 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 525 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 526 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 527 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 528 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 529 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 530 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 531 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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