Track Rod Ends & Rack Gaiters; To Refit Steering Column Assembly; Front Wheel Alignment - Lotus Evora Service Notes

Lotus Service Notes
7. Disconnect the steering angle sensor, and release its mounting bracket from the scuttle. Release the
clamp securing the sensor to the column.
8. Remove the front undertray and remove the pinch bolt securing the lower universal joint to the rack pinion
shaft and match mark the joint. Release the gaiter from the chassis aperture.
9. The column must be withdrawn complete with the two extruded alloy mounting brackets securing it to the
scuttle beam. For each of these two brackets, release the single front fixing into the top surface of the
scuttle beam, and the two rear fixings into the vertical face; all use threaded inserts in the chassis.
10. Withdraw the column assembly from the pinion shaft and through the fascia aperture.

To Refit Steering Column Assembly

New steering column assemblies are supplied without a steering lock barrel or ignition switch to allow
transfer of existing components. A plastic sleeve is fitted in the lock barrel bore for transit purposes.
CAUTION: Do not attempt to remove the plastic sleeve without following the procedure below. Failure
to heed this advice may result in the lock mechanism being irrepairably displaced, and a complete new
column assembly being required.
a) With the plastic sleeve still in place, and the ignition switch removed, use the lock spindle and the features
on the mechanism plate which interfaces with the lock barrel, to turn the lock mechanism to position 1 (to
match the features of the key lock barrel at this position). At this position, the column is unlocked.
b) As a precaution, maintain a pulling action on the lock spindle from now until the lock barrel is securely
installed.
c) Turn the plastic insert a quarter turn clockwise and withdraw. With the key turned to position '1', insert the
lock barrel into the lock housing and ensure that the spring loaded pin is engaged in the housing locating
hole.
d) The lock spindle may now be released.
Continue the assembly procedure in reverse to removal with the following notes:
- Slide the steering angle sensor and toe board gaiter over the intermediate column during installation.
- Torque tighten fixings as follows:
- Column 'break out' fixings; 24 Nm
- Column to forward fixing holes in extruded scuttle brackets; 24 Nm
- Extruded brackets to scuttle; 24 Nm
- Lower u/j pinch bolts; 25 Nm
HI.5 - TRACK ROD ENDS & RACK GAITERS

Front Wheel Alignment

Alignment is measured either by the angle the front wheels make with the vehicle's longitudinal axis, 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. The wheels are said to 'toe-in' when the wheel paths converge ahead of the vehicle,
and 'toe-out' when they diverge. Wheel alignment is designed to vary with both steering angle (Ackermann; to
minimise low speed, tight turn tyre scrub) and suspension travel (bump steer; to provide consistent handling)
and should be measured only 'straight ahead' at the specified mid-laden ride height.
Provision is made for the adjustment of front wheel alignment at the joint between the track rods, which
are ball jointed to the outboard ends of the steering rack, and the outer ball joints ('track rod ends') which con-
nect to the steering arms on the hub carriers. In this application, the track rod ends are extended to form the
major part of the track rods.
The mid-laden ride height and alignment specification is detailed in sub-section CK.2.
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Section HI