Lotus 2004 ELISE Service Notes page 88

Lotus Service Notes
Reassembly
Re-assemble the suspension in reverse order to disassembly with the following notes:
- Take care to assemble each pivot bolt with the correct washers/snubbers/spacers as shown in the dia-
grams.
- Smear the shank of each pivot bolt with PBC grease, but do not allow contamination of the threads.
- Take care to refit the original camber adjustment shimpack, and distribute the castor shims as noted on
removal.
- Top ball joint plinth fixing bolts:
The bolts securing the steering arm/top ball joint plinth to the hub carrier were upgraded in March '04 at
VIN serial number 1537 (approx.) in order to commonise with motorsport applications. Earlier type 8.8
grade bolts should be tightened to 45 Nm; Later 10.9 grade bolts to 68 Nm. The bolt grade is stamped
around the head of the bolt. The thread of both bolt types should first be treated with Permabond A130
(A912E7033V).
- After re-fitting a standard anti-roll bar, ensure that the crash structure closing panels are re-riveted.
- Lubricate the rubber type anti-roll bar mountings with rubber grease and the Nylon type with MoS
grease.
- Apply Permabond A130 (A912E7033V) to the threads of the steering arm bolts.
- Lubricate the ends of the damper top eye bush with rubber grease.
- Press the brake pedal to reposition the pads before driving the car.
- If the car suffers a suspension impact sufficient to damage a wheel rim, careful attention should be paid to
all related suspension components. Such forces can cause stretching of the lower ball pin and consequent
fixing nut torque loss. As a safety precaution, it is recommended that in all such cases, the lower ball joint
and the two bolts securing the upper ball joint plinth to the hub carrier are renewed.
The Service Schedule specifies that the security of the front and rear suspension is checked at each service.
For cars used on race tracks, or in similar conditions, suspension components and torque checks should be
carried out between sessions. This operation requires that all the principal suspension pivot bolts are torque
checked, noting the following points:
Where a bolt is tapped into a housing or weldnut, and relies on a thread locking compound for security, it
is important to appreciate that if the bolt is disturbed, the locking compound must be re-applied. The following
procedure should be adopted for all such fixings:
- Check the torque of the fixing.
- If the specified torque is attained without the fixing being disturbed (moving), take no further action.
- If the bolt moves, the locking action of the thread adhesive will have been compromised. Remove the
bolt completely, clean off all old adhesive using a wire brush and acetone, and apply new adhesive as
specified.
- Refit the bolt and tighten to the specified torque.
- If for any reason a bolt is found to have become loose, and the car has been operated for any period in
this condition, the bolt should be renewed as a standard precaution and related components carefully
inspected for hole ovality or wear.
Torque Settings:
Upper and lower wishbone pivot bolts
Upper swivel joint to steering arm
Lower swivel joint to plinth
Steering arm to hub carrier - 8.8 grade
Track rod end to steering arm
Damper to lower wishbone
Damper to top anchor bracket
Damper anchor bracket to chassis
Hub bearing unit to hub carrier
Brake calliper to hub carrier
Anti-roll bar alloy mounting clamps
Anti-roll bar drop links
Page 10
- 10.9 grade
Nm
45
55
55
45
68
30
45
45
25
90
45
25
45
Section CI
2