Lotus 2004 ELISE Service Notes page 414

Lotus Service Notes
2. Friction plate: Check the cush drive springs for breakage or cracking of the hub. Examine the condition
of the friction material for signs of oil contamination, scorching, or any other damage. Using vernier
callipers, measure the depth of the rivet heads below the surface of the friction material. Minimum depth:
0.3mm.
With the friction plate mounted on its splines, check the run-out at the outer edge of the friction surface.
Maximum run-out: 0.8mm.
If addressing symptoms of clutch judder, or if any of the above inspections are not passed, renew the
friction plate.
3. Release bearing: Check the bearing for discernible play, noise or rough feeling, and renew if there is any
doubt.
4. Flywheel: Using a dial test indicator, measure the axial run-out at the outer edge of the flywheel drive
surface.
Maximum runout: 0.1mm.
If necessary, renew the flywheel. When fitting the flywheel:
- progressively tighten the eight fixing bolts in a diametrically opposite sequence, to 49 Nm.
- mark the angular position of each bolt head, and further tighten each bolt in a diagonally opposite
sequence an additional 90°.
Refitting clutch assembly
1. Using a universal type centralising mandrel, position the friction plate with the 'flatter' side towards the
flywheel, and fit the clutch cover onto the flywheel dowels with the match marks aligned (if applicable).
2. Fit the clutch cover retaining bolts finger tight and monitor friction plate centralisation as the bolts are
progressively tightened in a diagonally opposite sequence to 19 Nm.
3. Using a dial test indicator, measure the diaphragm spring tip height variation. Maximum variation: 0.5mm.
If necessary, use a special clutch tool to achieve the specification.
4. If the release fork pivot ball had been removed, refit and tighten to 37 Nm.
5. Apply sparing quantities of Molybdenum Disulphide (MoS
fork fingers, release fork pivot, fork retaining spring and pushrod socket. Also apply sparingly to the
transmission input shaft splines.
6. Fit the release bearing and fork together, and position in the clutch housing with the fork retained on the
pivot ball by its retaining spring. Fit the dust boot into the housing aperture.
7. Refit the engine to the transmission in reverse order to removal, tightening the clutch housing bolts as
follows:
M12 x2; Upper
M10 x2; RH side
M10 x2; Starter Motor
M10 x2; Sump
Illustration overleaf.
64 Nm
37 Nm
37Nm
23 Nm
Section QH
) grease to the contact points of the release
2
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