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Table Of Contents - Lotus Evora Service Notes

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Vehicle Identification Number & Engine Number4

Lifting Points6

General Description9

Chassis Straightness Check10

Rear Subframe11

To Remove/Refit Rear Subframe11

Front Subframe12

To Remove/Refit Front Subframe12

Bodycare & Repair14

Table Of Contents14

Lotus Composite Body Features16

Accident Damage Assessment18

Paintwork Polishing18

Body Panel Bonding Materials19

Applicator Bottle19

Betaclean 3900 (A100B6008V)20

Betabrade F1 (A120B6043V)20

Betaclean 3300 (A120B6042V)20

Betawipe 4000 (A082B6355V)20

Betaprime 5404 (A082B6337V)21

Betaprime 1707 A+B (A111B6374V)21

Betaseal 1701 (A082B6281F)22

Plastic Panel Repair System22

Replacement Of Bonded-On Panels - General22

Windscreen Frame23

To Replace Windscreen Frame23

Body Side Panels24

To Replace Body Side Panel24

Rear Bulkhead25

Body Fittings27

Reservoir Access Hatch29

Access Panel Adjustment29

Tailgate Remove/Refit29

'A' Panel Removal/Replacement30

Front Clamshell31

Front Clamshell Removal/Replacement31

Rear Clamshell32

Rear Clamshell Removal/Replacement33

To Remove/Refit Rear Bumper35

Replacement Of Mirror Glass And Cover35

Replacement Of Mirror Assembly36

Door Shell, Beam & Hinges36

Door Weatherstrip Seals37

Drop Glass Waist Seal37

Door Weatherstrip37

Door Window, Guide Rails & Lift Mechanism38

Viewed From Outboard38

Door Glass Adjustment39

Door Glass Removal39

Guide Rail Removal39

Window Lift Mechanism39

Door Latch Mechanism40

Windscreen Removal/Replacement41

Exterior Release Handle41

Lh Door Exterior Lock41

Latch Mechanism41

Tailgate Glass43

Spillage Of Material43

To Replace Tailgate Glass43

Cabin Rear Window44

Rear Quarter Light Window44

To Replace Rear Quarter Light Glass44

Front Suspension46

General Arrangement47

Geometry & Adjustments48

To Be Revised49

Camber Adjustment50

Cambolt Effects50

Wishbone Pivot Bushes & Swivel Joints51

Cambolt Illustration51

Castor Adjustment51

Anti-Roll Bar52

Steering Swivel Joints52

Damper Pivots52

Suspension Disassembly/Assembly53

Damper And Spring53

Upper Wishbone53

Front Wheel Bearings55

To Replace Hub Bearing Assembly55

Rear Suspension56

Rear Suspension Layout57

Wishbone Pivot Bushes & Spherical Joints61

Upper And Lower Wishbones63

Rear Wheel Bearings64

General Layout67

Air Cleaner Element Inspection/Replacement68

Engine Oil & Filter Change69

Auxiliary Drive Belt70

Engine Removal/Replacement70

Auxiliary Belt Replacement70

Engine Special Tools72

Engine Repair72

Engine Management73

Diagnostic Trouble Code (Dtc) List75

Component Function79

Diagnostic Guide83

Camshaft Timing Control (Vvt)83

Crankshaft Position–Camshaft Position Correlation Error84

Intake Air Flow86

Barometric Pressure88

Intake Air Temperature89

Engine Coolant Temperature91

Sensor Connections91

Sensor Characteristics91

Throttle Position93

O2 Sensor (Pre Catalyst)97

Malfunction Criteria99

Potential Failure Modes99

O2 Sensor (Post Catalyst)100

Fuel Control System Too Lean Or Rich103

Fuel Injection System105

Knock Control System108

Engine Speed / Position Sensors109

Ignition System111

Catalyst System Efficiency112

Evaporative Emission Control – Leak Detection System114

Evaporative Emission Control – Purge, Open / Closed Circuit117

Fuel Level Sensor119

Engine Cooling Fan Control121

Vehicle Speed Sensor122

Idle Speed Control123

A/C Evaporator Temperature Sensor124

Battery Voltage125

Cruise Control126

Variant Code Not Programmed129

Fuel Pump Relay131

Vin Not Programmed Or Incompatible – Ecu/Pcm132

Throttle Actuator Control Range/Performance133

Air Conditioning System134

Variable Intake Manifold Circuit135

Clutch Position Sensor Circuit136

Air Intake Control Valve Circuit138

Coolant Recirculation Pump140

Throttle Actuator Control Motor Circuit/Open141

Throttle Actuator Control Motor Circuit/Low141

Throttle Actuator Control Motor Circuit/High141

Throttle Actuator Control System – Forced Idle142

Throttle Actuator Control System – Forced Engine Shutdown142

Throttle Actuator Control System – Forced Limited Power143

Throttle Actuator Control Module Processor143

Throttle Actuator Control Module Performance144

Pedal Position Sensor 'D' Circuit Low144

Pedal Position Sensor 'D' Circuit High145

Pedal Position Sensor 'E' Circuit Low145

Pedal Position Sensor 'E' Circuit High146

Throttle Position Sensor 'A'/'B' Voltage Correlation146

Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation147

Throttle Actuator Control System – High Airflow Detected147

A/C Refrigerant Distribution Valve148

A/C Compressor Lock Sensor Circuit149

Lost Communications With Tcm150

Lost Communications With Vdcm150

Lost Communications With Tpms150

Software Incompatible With Vdcm151

Emr.2 - Can Bus Diagnostics; Lotus Techcentre152

Transmission153

Gearchange Mechanism155

Gearchange Cable Adjustment156

Gearchange Cable Replacement157

Drive Shafts158

Lh Driveshaft Assembly158

Rh Driveshaft Assembly158

Driveshaft Assembly Replacement159

Driveshaft C.v. Joint And/Or Gaiter Replacement160

Extension Shaft Support Bearing160

Transmission Removal/Replacement162

Transmission Overhaul162

To Separate The Engine/Transmission Assembly162

Wheels & Tyres163

Tyre Pressure Monitoring System (Tpms)164

Tpms Fault Codes165

Winter Tyres & Snow Chains167

Punctured Tyre Emergency Inflator168

Column And Rack Assembly170

Power Steering Rack Operation171

Power Steering Schematic (Rhd Shown)173

Pas Fluid Check & Refill Procedure175

Steering Wheel175

Fluid Level Check175

To Remove Steering Wheel175

Steering Wheel Alignment176

Steering Column Assembly177

To Remove Steering Column Assembly177

Track Rod Ends & Rack Gaiters178

To Refit Steering Column Assembly178

Front Wheel Alignment178

Rack & Pinion Assembly Removal/Replacement179

Track Rod Ends179

Steering Rack Gaiters179

To Remove/Replace Steering Rack Assembly180

To Re-Fit/Replace Steering Rack Assembly180

Pas Pump Test Procedure180

Pas Pump Removal & Inspection181

Vane Pump Mechanism182

Braking System183

Tell Tale Lamps186

Brakes Tell Tale186

Brake Fluid Check & Change186

Brake Fluid Reservoir187

Renewal Of Brake Fluid187

Brake Bleeding Procedure187

Front Brake Shown188

Parking Brake Mechanism189

Parking Brake Shoes190

Parking Brake Lever190

Brake Disc Thickness190

Brake Callipers191

Brake Master Cylinder191

Rear Disc Replacement191

Vacuum Servo Unit192

Initial Movement192

Pressure Balance192

Tandem Servo Section (Brakes Off)193

Maximum Assistance193

Operational Check193

To Replace Brake Servo Unit194

Pedal Removal194

Abs Theory Of Operation195

Electro-Hydraulic Control Unit195

Anti-Lock Braking196

Sequence Of Operation197

Normal Braking197

Pressure Isolation (Pressure Maintain)198

Pressure Reduction199

Pressure Increase (Re-Apply)200

Brake Release201

Electro-Hydraulic Unit202

To Remove Electro-Hydraulic Unit202

Wheel Speed Sensors203

Data Link Connector (Dlc)203

Special Tools203

Lotus Techcentre203

'Lotus Techcentre' Checking Procedures204

Trouble Codes204

Abbreviations & Definitions205

Ecu Identification205

Diagnostic Trouble Codes206

Engine Cooling208

Thermostat Closed210

Thermostat Closed Circuit (Cold Engine)210

Thermostat Open Circuit (Normal Running Temperature)211

Re-Circulation Pump211

Drain/Refill Procedure212

Anti‑Freeze/Corrosion Inhibitor212

Radiator Fin Cleaning212

Radiator & Cooling Fans213

Radiator Fans213

Radiator Fan & Re-Circ. Pump Control214

Radiator Feed & Return Pipes214

Cooling Fans Control214

Evora Fuel System Layout217

Fuel Requirement & Filling219

Fuel Pressure Relief Procedure220

Fuel Pump/Tank Sender221

To Remove/Refit Fuel Pump Assembly221

Fuel Tank Removal/Refit222

Fuel Supply Test223

To Test Fuel Pump Output223

Charcoal Canister223

To Remove Pump/Sender Assembly223

Pfk 457 Vehicle Security Alarm226

Vehicle Security Alarm226

Transmitter Keys226

Disarming The Alarm/Unlocking226

Passive Immobilisation227

Arming The Alarm/Locking The Doors227

Turning Off The Interior Movement Sensor228

Opening The Tailgate228

Manual Activation Of Siren228

Transmitter Key Battery Replacement228

Programming Additional Transmitters229

Disconnecting The Car Battery229

Trigger Report Back And Feature Selection229

Location Of Alarm Components230

To Open The Doors From Outside230

Interior Door Lock Switch230

To Open The Doors From Inside231

Locking The Doors Mechanically231

Inertia Switch231

Cdl Component Location231

Switches & Instruments - Driver's Information234

Ignition Switch/Steering Lock234

High Rpm Tell Tales235

Turn Tell Tale235

Rear Foglamp Tell Tale236

Passenger Airbag Off Switch236

Scheduled Service Tell Tale236

Engine Malfunction Indicator Lamp236

Traction Control Tell Tale237

Abs Tell Tale237

Brake Tell Tale237

Oil Pressure Tell Tale237

Seat Belt Tell Tale238

Airbag Tell Tale238

Fuel Level Display239

Ambient Air Temperature Display239

Information Switch239

Trip Recorder240

Coolant Temperature Display240

Ambient Temperature Units240

Tyre Pressure Units (If Tpms Is Fitted)240

Door/Tailgate Open Display241

Lighting Switches241

Sidelamp Switch241

Headlamp Switch241

'Lights On' Warning242

Rear Fog Lamp Switch (Where Fitted)242

Reversing Lamp, Parking Aids And Reversing Camera242

Hazard Warning Lamps Switch242

Steering Column Lever Switches243

Turn Indicators/Headlamp Flash/Dipswitch243

Wiper Functions243

Windscreen Washer Functions243

Headlamp Powerwash244

Passenger Airbag Defeat (Pab) Switch244

Interior Lighting244

Lotus Traction Control245

Sport Mode (If Fitted)245

Component Location & Fuse Ratings247

Main Fusebox247

Slot Rate Circuit247

Front Relay Blocks248

Integrated Control Module248

Key To Icm Diagram249

Rear Fusebox250

Component Location251

Audio Equipment251

Battery Access252

Disconnecting The Battery252

Battery Reconnection252

Wiper Mechanism253

Quiescent Drain253

Battery Cables253

Harness Routing254

To Remove The Wiper Mechanism254

Headlamp Assemblies255

Xenon Headlamp Assemblies255

Headlamp Servicing255

Headlamp Housing Removal255

Bulb Replacement256

Headlamp Beam Alignment256

Headlamp Units256

Hid Xenon Headlamps (If Fitted)256

Rear Lamp Cluster Bulbs257

Rear Fog And Reverse Lamps257

Side Repeater Lamps257

Licence Plate Lamps257

Circuit Diagrams258

Maintenance & Lubrication308

Recommended Lubricants309

'Severe Service' Conditions310

Special Operating Conditions311

Additional Servicing311

Pre-Delivery Inspection314

Pre-Delivery Paint Mark Up - Evora316

Licence Plate Fitment317

Air Conditioning, Heating & Ventilation318

Heater Circuit320

Air Conditioning - Basic Principles320

Closed Circuit320

Receiver-Drier321

Expansion Valve321

Heater/A.c. Airflow Overview322

Interior Climate Controls323

Distribution Control323

Face Level Vents323

Face Level Vents & Footwells324

Footwell Vents324

Footwells & Windscreen324

Temperature Control325

Interior Fan325

Re-Circulation Switch325

Heated Rear Screen326

Pollen Filter326

Engine Bay Ventilation326

Cooling Fans & Re-Circulation Pump326

Refrigerant Handling327

Refrigerant Pipework Precautions327

Refrigerant Pipework Fixing Torques328

Refrigerant Pipework 'O' Rings328

Refrigerant Oil329

Approved Oils329

Compressor Removal329

Oil Quantity Adjustment Prior To Compressor Refitment330

Refitting Existing Compressor330

Fitting New Compressor330

Compressor Fitment331

To Remove Condenser331

Heater/Evaporator/Fan (Hvac) Unit332

To Remove Hvac Unit332

Air Distribution Unit (Adu)333

To Remove The Air Distribution Unit333

Refrigerant Pipes334

Clutch Pedal337

Hydraulic Release System337

Master Cylinder337

To Replace The Master Cylinder337

Slave Cylinder338

Hydraulic Pipe338

Clutch Assembly339

Inspection & Replacement339

Technical Data - Engine340

Technical Data - Vehicle344

Interior Trim348

To Remove/Refit Door Trim Panel351

Door Trim Panel Components351

Door Sill Trim Panel351

Trim Feature Strip & Mood Lighting351

Lower 'A' Post Trim Panel352

Centre Console352

Fascia Dash Panel352

Fascia Lower Panels353

Main Fascia Panel353

Steering Column Shroud353

Windscreen Pillar Trim Panels354

Rear Quarter Panels354

Rear Seat Backrest Or Bulkhead Pad354

Airbag System356

Can Bus Diagnostics359

Safety Precautions, Shipping, Storage & Disposal360

Sensor & Diagnostic Module (Sdm) & Forward Crash Sensors360

Inflator Module360

Vehicle Scrapping Procedures361

Deployed Inflator Modules362

Inspections Required After An Accident362

Sensor & Diagnostic Module (Sdm)362

Frontal Impact Sensing And Deployment363

Fault Display363

Power Supply & Grounding364

Supply Voltage Range364

Energy Reserve364

To Replace Sdm364

Driver Airbag Module365

To Replace Driver's Airbag365

Rotary Connector366

To Replace The Rotary Connector366

Passenger Airbag Module367

To Replace Passenger Airbag367

Seat Belt Pre-Tensioners368

Device Operation368

To Replace Front Seat Belt Assembly369

Safety Standard369

Transportation Of Belt With Pre-Tensioner370

Storage Of Belt With Pre-Tensioner370

Disposal Of Belts With Pre-Tensioner370

Vehicle Disposal370

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