Lotus 2004 ELISE Service Notes page 399

Lotus Service Notes
PL.7 - COMPRESSOR
The a.c. compressor is mounted on the left hand side of the cylinder block, beneath the alternator, and is
accessible from below.
A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump,
alternator and a.c. compressor, with a slave pulley fitted in place of the power steering pump used in other
applications. A hydraulically damped, spring loaded tensioner arm applies tension to the back of the belt, and
is maintenance free. The belt itself should be inspected for condition at each service interval, and if it exhibits
any evidence of physical damage, cracking, fraying, perishing, abrasion or contamination, it should be re-
placed. In the case of oil or coolant contamination, the cause must be identified and rectified, and each of the
pulleys must be thoroughly degreased before the new belt is fitted.
For further details, refer to section CH in the Engine Repair Manual, but note that only a six-point socket
should be used on the cast hexagonal boss on the tensioner arm. The manufacturing draft angle on this
component may result in damage being caused by a twelve point socket.
Compressor Removal
1. Remove the compressor drive belt by applying a six-sided socket to the cast boss on the tensioner arm
to relieve the tension, and slip the belt off the compressor pulley.
2. Recover the refrigerant using equipment connected to the service ports at the right hand front of the
engine bay.
2. Remove the engine bay undertray.
3. From beneath the car, release the suction and discharge pipes from the compressor and immediately cap
the pipes and compressor ports to prevent ingress of dirt and moisture.
4. Disconnect the compressor clutch harness.
5. Release the three compressor fixing bolts, and remove the compressor from the engine. Retain the
compressor for oil quantity measurement if a new unit is to be fitted.
Oil Quantity Adjustment Prior to Compressor Refitment
Refitting Existing Compressor
i) If the existing compressor is to be refitted after normal refrigerant recovery has been performed, a quan-
tity of oil equivalent to that recovered must be added to that already held in the compressor.
ii) If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost. Drain the remaining oil from the compressor by removing the drain
plug and rotating the clutch plate. Add 60 cm³ of new refrigerant oil (see above) to the compressor before
refitment.
Fitting New Compressor
New compressors are sealed and pressurised with nitrogen gas. The sealing caps should be removed
only immediately prior to compressor fitment, at which time the gas pressure should be heard to escape as a
cap is slowly released. New compressors are supplied with an oil fill of 60 cm³.
iii) If normal refrigerant recovery has been performed, the new compressor oil should be drained off, and the
required oil quantity in the new compressor calculated and added:
- Drain and measure the oil quantity in the OLD compressor by removing the drain plug and rotating
the clutch plate. Quantity = X cm³
- Oil quantity to be added to new compressor = X + 10 cm³
iv) If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost. In this case, drain the new compressor of oil and refill with 60 cm³.
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Section PL