Lotus Elise Service Notes page 107

Lotus Service Notes
Section TDM
EE.3 - ENGINE REMOVAL/REPLACEMENT
The engine may be removed from above, with or without the rear clamshell in position. It is recom-
mended to remove the clamshell for improved access, and to reduce the possibility of paint damage. If the
clamshell is left 'in situ', the luggage comopartment divider panel (if fitted) must be removed in order to allow
the power unit to be turned thro' 90° as it is withdrawn.
The operation is best performed on a wheel free lift as in order for the driveshafts to be withdrawn, the
upper ball joints must by released from the hub carriers.
1. Fuel Pressure Relief Procedure
The fuel line between pump and injector rail, and the injector rail itself, contain pressurised fuel
both when the engine is running, and after switching off. The following procedure must be used
before disconnecting the fuel feed line:
Pull out the fuel pump 10A fuse (to the rear of the ECM), start the engine (if possible), and run until it
stops from starvation. Crank the engine for a further 10 seconds.
If the engine is a non-runner, pull out the fuel pump fuse, and crank the engine for a total time of 60
seconds to minimise residual fuel pressure.
Disconnect the battery.
Use a shop towel to absorb the small amount of pressurised fuel remaining as the fuel feed pipe is
disconnected at its push fit connector between the fuel filter and fuel rail inlet hose; pull back the collar to
release the grip of the connector on the pipe. Plug the pipe ends.
In a similar manner, disconnect the low pressure fuel return hose.
2. To remove the rear clamshell, refer to Section BN.
From beneath the car:
3. Drain the coolant and transmission oil.
4. Remove the exhaust downpipe between the exhaust manifold and catalytic converter.
5. Remove the gear cables from the transmission lever spigots (prise off), and pull off the spring clips
retaining the outer cables to the abutment bracket.
6. Release the earth braid from the transmission end case, and the throttle cable from the sump 'P' clip.
7. Release the engine steady arm from its anchor bracket on the rear of the the sump.
8. At each side of the car;
Release the two bolts securing the top ball joint plinth to the hub carrier, taking note of the camber
adjustment shim plates.
The inboard C.V. joint is retained in the transmission by a rounded section circlip, and may be
removed using a special wedge tool T000T1276, or by applying a shock pull to the C.V. joint body
using a slide hammer with a forked end.
CAUTION: Do NOT attempt to remove the inboard C.V. joint from the transmission by pulling on the
driveshaft. This action will cause the joint to become disassembled and may entail replacement of the
joint. The components of the inboard plunging joint are held in position, for transit purposes only, by a
collar within the boot which will be overidden if excessive axial force is used. Apply pressure only to the
'tulip' or outer body of the joint.
Withdraw the inboard C.V. joint from the transmission, and fit blanking plug T000T1385 into the
transmission to limit the amount of transmission oil loss.
From above:
9. Release the air cleaner mounting plate from the chassis, and release the fuel filter mounting from the
plate. Withdraw the plate complete with air cleaner assembly.
10. Remove the header tank: Disconnect the two hoses, release the two fixing bolts, and withdraw the tank.
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