Lotus 2004 Eleven Service Notes page 461

Lotus Service Notes
To remove heater/evaporator/fan unit:
1. Remove the front clamshell (see sub-section BR.6).
2. Remove the two air deflector/water shields, windscreen washer reservoir and ducting between heater/
a.c. unit and air distribution unit.
3. Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.
4. Disconnect the refrigerant pipes as necessary and remove the receiver-drier unit and mounting bracket.
Disconnect the outlet pipe from the expansion valve. Cap all pipes and ports immediately to prevent the
ingress of dirt and moisture.
5. Disconnect the hoses from the heater matrix and collect escaping coolant.
6. Unplug the wiring harness from the temperature flap motor, a.c. thermostat and fan motor.
7. Remove the clamping bridge retaining the unit into the chassis and release the overcentre clips securing
the unit to the fan blower housing. Withdraw the unit from the chassis together with the drain tube.
To refit heater/evaporator/fan unit:
Before refitting the unit, first ensure that the following components are fitted in the chassis:
- Fresh air intake ducting/re-circulation valve assembly, retained in channel at front of chamber by single
clamp bracket. Check that re-circ. flap stepper motor harness is connected, and that the moulded plastic
water shield is fitted over the actuator.
-
- Recirc. ducting is fitted in rear of chassis climate chamber
- Earth cables are connected to chassis negative post at the left hand side of the chamber.
- Rear circuit brake pipe is fitted between master cylinder and bulkhead connector.
Position the fan housing into the passenger side of the chassis chamber. Fit the drain tube into the base
of the heater/evap. unit and use a guide wire or similar to aid routing of the tube through the chassis crossmember
via the central aperture at the back of the chamber, as the unit is fitted into the chamber. Engage the lower
edges of the fan unit and heater/evap. unit before clamping together with the two overcentre latches. Retain
the assembly by fitting the bridging clamp bracket.
Continue re-assembly in reverse order to removal.
PL.12 - AIR DISTRIBUTION UNIT
The airflow distribution unit is mounted on top of the chassis scuttle, sandwiched between the underside
of the fascia top/demist duct and the chassis. The unit comprises several plastic mouldings bonded and
rivetted together to contain the rotary flap for windscreen/face level vents, and also the footwell flap. The
stepper motor for the rotary flap is mounted on the side of the unit.
To Remove
1. Remove the front clamshell (see sub-section BR.6) and washer bottle and wiper mechanism (see sub-
section MP.8).
2. Remove the air trunking between the heater/a.c. unit and the distribution unit.
3. Release the fixings securing the heater water pipe to the chassis scuttle.
4. Drill out the rivets securing the distribution unit retaining bracket to the chassis scuttle.
5. Withdraw the unit from beneath the scuttle baffle panel, disconnecting the stepper motor harness plug
when access allows.
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Section PL