Lotus Elise Service Notes page 519

Lotus Service Notes
Section XA
Delete IAC valve: Remove the idle air control valve, mounting bracket and plumbing. Fit blanking plugs to the
inlet tract spigots on manifold underside. Fit blanking grommet to backplate.
Fit breather hose kit: Remove the screenwash bottle and battery clamp bracket from the front chassis well.
Cut the top, bottle mounting portion, of the bracket from the lower, battery clamp, section, and paint protect the
cut surface. Rivet the bottle mounting bracket to the LH side of the engine bulkhead, and fit the washer bottle
with motor aperture blanking grommet, to the bracket to act as oil catch tank. Remove the breather hose
between cam cover and airbox, and fit the grommet to the airbox hole. Use the breather hose kit to connect the
two cam cover breather spigots to the catch tank, cutting a 13 mm hole in the top surface of the bottle to admit
the breather hose, and a similar hole in the bottle filler cap to allow breathing.
Fit race exhaust system: Remove the catalytic converter and standard muffler, and replace with the track
muffler.
Fit lower temp, thermostat: Replace the standard 88°C thermostat with the 82°C thermostat.
Exchange ECM: Replace the standard ECM with the reprogrammed unit, and return old unit to Lotus.
RHD only: Fit oil cooler kit: See separate instruction sheet LSL388.
101' MOP Inlet Cam Pullev:
The standard engine inlet cam timing is 105° ATDC maximum opening point. The modified pulley supplied in
the kit allows the inlet cam timing to be advanced by 4° to 101° MOR
1. Remove the timing belt top cover.
2. Turn the engine to align the timing mark on the crankshaft front pulley with the 'safe' position 45° ATDC
mark (12 O'clock) on the timing belt lower cover. Check that the camshaft pulley timing marks are
aligned towards each other; if not, turn a further 360°.
3. Slacken the belt tensioner clamp bolt, and remove tension from the cam belt.
4. Use special tool T000T1280 to hold the inlet camshaft pulley and release the retaining bolt. Withdraw the
pulley from the camshaft and timing belt.
5. Fit the new pulley to the camshaft with the T mark just above the timing mark on the exhaust camshaft
pulley and the dowel engaged in the pulley slot. Use special tool T000T1280 to hold the inlet camshaft
pulley and tighten the M10 retaining bolt to 65 Nm
6. Turn the inlet camshaft to align the inlet pulley T mark with the exhaust pulley 'EXHAUST' mark, and slip
the belt onto the pulleys ensuring that the drive side of the belt is tight and the crankshaft pulley is still
positioned at the 90° ATDC mark.
7. Using a 6mm hex. key, rotate the tensioner counterclockwise and align the centre of the indent on the
tensioner pointer with the index wire ensuring that the pointer approaches the index wire from above. If
the pointer passes the wire, release the tension completely and repeat the procedure.
8. Ensuring that the pointer does not move, tighten the tensioner bolt to 25 Nm.
9. Using the crankshaft pulley bolt, slowly turn the crankshaft 2 turns clockwise to check there is no valve/
piston contact, and re-align the timing marks without having to 'back up'. Check that the tensioner pointer
is still correctly aligned with the index wire. If not, slacken the tensioner bolt until it is just possible to
move the lever clockwise, and position the pointer just above the index wire. Continue with operation (7).
10. Refit the belt guards.
Clutch Kit
The clutch kit is a direct replacement for the standard components. See Service Notes section QF.
Bpfly pqcK
Rear diffuser panel: Remove the rear diffuser panel, and replace with the new (standard Elise) panel using new
mounting struts which attach to pre-drilled holes in the subframe top rear flange.
Carbon fibre headlamp blanking panels: Remove the headlamp and turn indicator lamps, and cut the lamp
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