Pedal Box; To Replace Brake Servo Unit; Pedal Removal - Lotus Evora Service Notes

Lotus Service Notes
Setting brake pedal: It is essential that the servo piston (and master cylinder piston) is allowed to return fully
when the brakes are released, and is not pre-loaded by mal-adjustment of the input pushrod. See (4) below.
Stop light switch: The stop switch is mounted in a right angle bracket fixed to the underside of the scuttle, and
abuts directly against the pedal. The switch is retained in the bracket by a quarter turn mechanism, with no
adjustment provided or required.

To Replace Brake Servo Unit

1. Remove the brake master cylinder (see sub-section JL.7).
2. From within the footwell, disconnect the servo pushrod from the brake pedal.
3. Disconnect the brake servo vacuum hose, and release the four nuts securing the servo to the pedal box
extension plinth. Withdraw the servo assembly.
4. Before replacing a servo unit, first check the adjustment of the clevis on the input pushrod (i.e. the effective
length of the pushrod). With a new rubber gasket fitted over the four servo mounting studs, the perpen-
dicular distance from the surface of the gasket to the axis of the clevis pin hole should be 133mm.
5. Replace the servo in reverse order to the above, tightening the servo mounting nuts to 25 Nm, and the
master cylinder new fixing nuts to 25 Nm. Check pushrod adjustment (see sub-section JL.9) and bleed
the hydraulic system (see sub-section JL.3)
JL.10 - PEDAL BOX
The pedal box is fabricated from alloy sheet, and rivetted, bolted and bonded to an aperture in the chassis
scuttle. A hollow steel pivot shaft serving the brake and clutch pedals is bolted to a steel mounting plate, itself
bolted to the inside of the pedal box. The brake and clutch pedals are fabricated from steel plate, and feature
synthetic bushes for maintenance free articulation on the steel pivot shaft, and serrated alloy footpads. The
brake pedal uses a coil pull off spring, and the clutch pedal is equipped with an overcentring coil spring linkage,
in order to reduce the pedal effort required to maintain full clutch disengagement. A clutch pedal potentiometer
is also fitted in order to provide data for Cruise Control operation, and for the start inhibit function on Canadian
market cars.
The 'drive by wire' throttle actuation uses a steel rod fabricated pedal to operate an electronic module and
provide a signal to the engine ECU, which then actuates the throttle valve stepper motor within programming
constraints. The throttle pedal module is secured to a mounting bracket by three bolts, with a further three bolts
fixing the bracket to the pedal box.

Pedal Removal

To remove the throttle pedal assembly complete with mounting bracket, disconnect the harness plug from
the module, and remove the three bolts securing the bracket to the pedal box.
To remove a brake or clutch pedal from the pivot shaft, the pedal shaft mounting plate must be removed
from the pedal box complete with the brake and clutch pedals:
1. Unplug and remove the throttle pedal assembly complete with mounting bracket by releasing the three
screws securing the bracket to the pedal box.
2. Disconnect the brake and clutch pedals from their pushrods, and unhook the brake pedal return spring.
3. Unplug and remove the clutch pedal position switch with mounting bracket, by releasing the two bolts
securing the bracket to the pedal box.
4. Release the clutch pedal assistor spring anchor bracket from the pedal box side (3 bolts).
5. Remove the two bolts securing the clutch master cylinder assembly to the pedal box and support the
cylinder aside.
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Section JL