Lotus 2004 Eleven Service Notes page 290

Lotus Service Notes
To refill the system:
1 Refit the hoses to the feed and return pipes and close the cylinder block drain tap.
2. Remove the right hand front wheelarch liner and open the air bleed plug on the radiator outlet hose. From
within the engine bay, open the air bleed plug in the heater return hose at the left hand rear of the engine
bay.
3. Fill with the recommended coolant mix via the header tank and close the bleed plugs when a steady
stream of coolant is expelled.
4. Start the engine and allow to idle, and periodically open the bleed plugs to allow any trapped air to be
expunged. Top up the header tank when necessary, and fit the pressure cap when required to prevent
overflow. When the cooling fans have cut in and then out, stop the engine and allow to cool. Recheck
coolant level when fully cold.
KH.4 - RADIATOR & COOLING FAN
The aluminium cored radiator is positioned horizontally on top of the composite 'crash structure' in the
front services compartment. A composite moulding is used to mount the radiator, and also, via extensions at
each side, to provide a mounting point for the inside front of the clamshell wheelarch. The radiator must be
removed for access to the cooling fans.
To Remove Radiator
1. Remove the front clamshell (see section BR).
2. Drain the coolant and disconnect the feed and return hoses from the radiator.
3. If the car is equipped with air conditioning, de-pressurise the system and recover the refrigerant via the
service ports near the evaporator.
4. Remove the two radiator outlet air deflector panels, release all tie wraps and fixings securing wiring
hanesses and pipes to the radiator mounting panel, and disconnect the radiator fan harness plugs.
5. If the car is fitted with front mounted oil coolers, disconnect the feed and return hoses from both coolers
and plug all ports to limit oil spillage. Remove the mounting brackets from the coolers and crash struc-
ture.
6. Release the single fixing at the bottom of each side extension securing the mounting panel to the bottom
flange of the crash structure.
7. Release the three fixings securing the back edge of the mounting panel to the vertical flange on the crash
structure, and the three fixings along the front edge of the panel.
8. Withdraw the radiator mounting panel with radiator/(condenser)/cooling fans assembly.
9. Each cooling fan is secured two studs and nuts to either the radiator flange bracket, or, on a.c. cars to the
condenser. The condenser is secured to the radiator lower flange by two studs at the front edge, and by
two pairs of screws at the rear edge. The radiator is fixed to the mounting panel by brackets at the front
and rear. Note the foam packing used between the radiator and mountign panel to ensure that all ducted
air flows through the radiator matrix.
10. Refit the radiator in reverse order to removal, ensuring that the foam packing is re-installed. Refill with
coolant and bleed as detailed in sub-section KH.3. Re-charge refrigerant system.
Section KH
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