User Manuals: Lotus Elise 2001 Sports Car

Manuals and User Guides for Lotus Elise 2001 Sports Car. We have 1 Lotus Elise 2001 Sports Car manual available for free PDF download: Service Notes

Lotus Elise 2001 Service Notes (481 pages)

Brand: Lotus | Category: Automobile | Size: 13 MB

Contents
3
Introduction
4
Vehicle Identification Number & Engine Number
4
Engine Bay Undertray/Diffuser
5
Jacking Points
6
Technical Data - Engine
7
Technical Data - Vehicle
10
Chassis
14
General Description
16
Chassis Straightness Check
17
Rear Subframe & Longerons
18
To Remove Rear Subframe Assy
18
Fitting Rear Subframe
18
Fitting Rear Longerons
18
Bodycare & Repair
20
Body Panels
21
Lotus Composire Body Features
22
Bodycare
23
Soft Top Roof
23
Accident Damage Assessment
24
Paintwork Polishing
24
Ventilation
24
Body Panel Bonding Materials
25
Front Crash Structure
29
Windscreen Frame
31
To Replace Windscreen Frame
32
Windscreen Frame Bonding
34
Sill Panels
35
To Replace Sill Panel
35
Rear Bulkhead
36
To Fit Bulkhead Panel
37
Body Fittings
38
Roof
39
Soft Top Canopy
39
Soft Top Fitting
39
Soft Top Removal
40
Front Bonnet Panels
41
Engine Cover Lid
41
Door Hinge Cover Panel
43
Front Clamshell
43
To Remove Front Clamshell
43
Rear Clamshell
45
To Remove Rear Clamshell
45
Door Mirrors
46
Replacement of Mirror Plinth
47
Door Beam & Hinge
47
Door Hinge Adjustments
47
Door Beam Pivot Bearings
48
Door Shell Assembly
49
Removal of Door Shell from Beam
49
Door Glass, Guide Rails & Winder Mechanism
50
Door Glass Adjustment
50
To Replace the Door Window
52
To Replace Door Winder Mechanism
52
Door Seals
53
Door Glass Guide Rails
53
Drop Glass Waist Seal
53
Door Latch Mechanism
54
Door Weatherstrip
54
Interior Release Handle
55
Exterior Release Button
55
Latch Mechanism
56
Relay Lever Mechanism
56
Instrument Binnacle & Dash Panel
57
To Remove Fascia Top Panel
57
To Remove Dash Panel
58
Windscreen
60
To Replace Windscreen
60
Decal Positioning
63
Spillage of Material
63
Shelf Life
63
Front Suspension
64
General Layout
65
Camber Adjustment
67
Castor Adjustment
68
Top Wishbone Inboard Fixing
69
Anti-Roll Bar
69
Anti-Roll Bar Mounting
70
Anti-Roll Bar Drop Link
70
Suspension Disassembly/Assembly
71
Front Wheel Bearings
72
To Replace Hub Bearing Assembly
72
Rear Suspension
74
Rear Bump Steer Adjustment
81
Bump Steer Measurement Procedure
82
Rear Wheel Bearings
83
Engine
84
Engine Oil Level Check
85
Engine Oil Change
85
Oil Filter
86
Used Engine Oil
86
Air Cleaner Element
87
Alternator Belt
87
Spark Plugs
88
Engine Removal/Replacement
89
Fuel Pressure Relief Procedure
89
Special Tools
90
Repairs and Replacements
93
Engine Number Location
94
Engine Serial Number Prefixes
94
Cylinder Head Components
101
Timing Belt Components
108
Front Timing Belt Components
111
Rear Timing Belt Components
112
Engine Operation
113
Crankcase Ventilation
117
Camshaft Timing Belt
118
Flywheel Fitted with a Reluctor Ring
127
Cylinder Head Bolts Inspection
242
Test with Cylinder Head Removed
242
Test with Oil Rail Removed
242
Crankshaft, Main & Big-End Bearings
243
Pressed Steel Sump
244
Alloy Sump
244
Big End Bearings
245
Crankshaft Removal
246
Crankshaft Inspection
247
Main Bearings Selection
249
Main Bearings Size Selection Table
249
Main Bearings Type Table
249
Big End Bearings Selection
250
Big End Bearings Size Selection Table
250
Crankshaft, Main and Big-End Bearings - Refit
251
Piston to Cylinder Liner Bore Clearance
258
Piston Rings
258
Cylinder Liners
259
Pistons and Connecting Rods - Refit
261
Engine Management & Fuel Injection
269
Component Location Diagram
270
Key to Component Location Diagram
271
Throttle Cable Adjustment
272
Engine Control Unit
273
To Replace the ECU
273
Relay Module
274
Inlet Air Temperature & Manifold Absolute Pressure Sensor
275
Crankshaft Position Sensor
276
Engine Coolant Temperature Sensor
277
Throttle Position Sensor
278
Idle Air Control Valve
279
Oxygen Sensors
280
Camshaft Position Sensor
281
Fuel System
282
Fuel Pump Switching
283
Push Fit Connectors
285
Fuel Injectors
285
Fuel Rail and Pressure Regulator Valve
286
Ignition System
288
To Replace Ignition Coil
288
Scanner Tool
289
Trouble Code Diagnosis
290
Manifold Absolute Pressure
292
Circuit Range/Performance Problem
292
Circuit Low Input
292
Circuit High Input
292
Intake Air Temperature
293
Engine Coolant Temperature
294
Throttle Position
295
02 Sensor
296
Fuel Control System too Lean or Rich
298
Injector Circuit Malfunction
299
Misfire
300
Engine Speed / Position Sensors
301
Crankshaft Position Sensor Circuit Malfunction
301
Catalyst System Efficiency
302
Evaporative Emission Control System
303
Vehicle Speed Sensor
304
Idle Speed Control
305
RPM Lower than Expected
305
RPM Higher than Expected
305
Battery Voltage
306
ECU Integrity
307
Fuel Pump
308
Relay or Circuit Open
308
Relay or Circuit Shorted
308
Misfire Learns Not Complete
310
Coolant Fan Relay
311
Air Conditioning Control Relay
312
Transmission
313
Gearchange Mechanism
314
Gearchange Cable Adjustment
315
Gearlever Replacement
316
Gearchange Cable Replacement
318
Gearlever Mounting Bracket
318
Lubrication
318
Drive Shafts
318
Driveshaft Replacement
319
Driveshaft C.V. Joint And/Or Gaiter Replacement
320
Transmission Replacement
321
Transmission Overhaul
322
PG1 Manual Gearbox
324
Gearbox Identification
326
Manual Gearbox
328
Gearbox Components
329
Sectioned View of Gearbox
330
Operation - Torsen Differential
332
Description - Reverse Brake
334
Operation - Reverse Brake
335
Gearbox Dismantling
336
Component Dismantling
343
Input Shaft
343
Output Shaft
343
Synchro Assemblies
344
Synchro Assembly Components
344
Synchro Assembly Identification
345
Selector Shafts
346
Selector Shaft Components
346
5Th/Reverse Selector
347
Interlock Assembly
347
Differential Assembly
347
Inspecting Components
348
Input and Output Shaft Assemblies
348
Reverse Idler Shaft and Gear
349
Selector Shafts and Forks
350
Torsen Differential
352
Differential Housing
352
Component Assembling
354
Differential
354
Input Shaft Gear End-Float
356
Output Shaft Gear End-Float
358
Input Shaft End Thrust
359
Differential Pinion Gear Backlash
360
Differential Bearing Pre-Load
361
Standard and Torsen Differentials
361
Gearbox Assembling
362
Wheels & Tyres
367
Wheel Bolts
369
Winter Tyres & Snow Chains
370
Punctured Tyre Emergency Inflator
371
Steering
372
Steering Wheel
373
To Remove Steering Wheel
373
Steering Wheel Alignment
374
Upper Column Assembly
375
Dimensional Check
376
Outer Column
376
Inner Column Lower
376
To Remove Upper Steering Column Assembly
377
Intermediate Column
378
Track Rod Ends & Rack Gaiters
379
Front Wheel Alignment
379
Track Rod Ends
379
Steering Rack Gaiters
379
Rack & Pinion Assembly Removal/Replacement
380
To Remove/Replace Steering Assembly
380
Adjustment of Rack Bar Thrust Pad
381
Brake System & Pedal Box
382
Brake Fluid Check & Change
384
Front Brake Pad Replacement
385
Renewal of Brake Fluid
385
Rear Brake Pad Replacement
386
Parking Brake Mechanism
387
Brake Discs
390
Front Disc Replacement
390
Rear Disc Replacement
390
Brake Master Cylinder
391
To Replace Seals
391
Assemble the Front Piston
392
Assemble the Rear Piston
392
Pedal Box
394
Viewed from above
396
Pedal Trunnion Bushes
397
Caliper Overhaul
397
Rear Caliper Sliding Pins
398
Engine Cooling
399
Thermostat Closed
400
Thermostat Open
400
Maintenance
401
Drain/Refill Procedure
402
Anti-Freeze/Corrosion Inhibitor
402
Radiator Fin Cleaning
402
Radiator & Cooling Fan
404
To Remove Radiator
404
Radiator Fan Control
406
Radiator Feed & Return Pipes
407
Fuel System General Layout
409
Fuel Filling
410
Fuel Requirement
410
Fuel Filter
411
Fuel Tank
412
To Remove Fuel Tank
413
Fuel Pump/Sender Assembly
415
To Test Fuel Pump Output
416
Charcoal Canister
417
To Remove Pump/Sender Assembly
417
Re-Fitting Pump/Sender Assembly
417
Control System
419
Roll over Valve
419
Electrics
420
Vehicle Security Alarm
421
Keys
421
Standard Immobiliser
421
Upgraded Security System
421
Disarming the Alarm
422
Intrusion Sensing
422
Transmitter Key Battery Replacement
423
Disconnecting the Vehicle Battery
423
Component Location
423
Replacement Transmitter Keys
424
Ignition Switch/Steering Lock
425
Tell Tale Lamps
425
Bulb Check
425
Turn Tell Tale
425
Brakes Tell Tale
426
Oil Pressure Tell Tale
426
Seat Belt Tell Tale
426
Alarm Tell Tale
426
Instruments
427
Speedometer
427
Tachometer
427
LCD Display Panel
427
Fascia Switches
428
Odometer
428
Trip Recorder
428
Sidelamp Switch
428
Column Switches & Horn
429
Auxiliary Power Socket
429
Headlamp Dipswitch
429
Windscreen Wiper/Washer
429
Interior Lamp
430
Windscreen Washer
430
Horn
430
Component Location & Fuse Ratings
431
Main Fusebox
431
Engine Compartment
431
Audio Equipment
433
Aerial
433
Speakers
433
Battery
434
Battery Access
434
Disconnecting the Battery
434
Battery Reconnection
434
Battery Charging
435
Quiescent Drain
435
Battery Cables
435
Wiper Mechanism
437
Harness Routing
438
Front Lamp Assemblies
439
Headlamp Units
439
Front Turn Lamps
439
Circuit Diagrams
440
Start, Alternator & Ignition
441
Fuel Pump - Cooling Fan Engine Management
442
Engine Management System
443
Alarm & Interior Lamp
444
Stop & Reverse Lamps
445
Direction Indicators & Hazard Lamps
446
Headlamps Sidelamps & Fog Lamp
447
Windscreen Wipers
449
Interior Fan / Air Conditioning
450
Radio & aux Power Socket
451
Power & Ground Structure
452
Inter-Harness Connectors
453
Air Bag & Option
454
Maintenance & Lubrication
455
Recommended Lubricants
456
Maintenance Schedule
457
Pre-Delivery Inspection
460
Body Paint Inspection
462
Heating & Ventilation
463
Heater Circuit
465
Heater System Components
465
Control Cables
466
Heater Unit
468
Air Distribution Unit
468
Clutch
469
Hydraulic Release System
472
Master Cylinder
472
To Replace the Master Cylinder
472
To Overhaul the Master Cylinder
473
Slave Cylinder
474
To Replace the Slave Cylidner
474
To Overhaul the Slave Cylinder
475
Hydraulic Hose
475
Replacing Hydraulic Hose
476
Clutch Assembly
477
Removal of Clutch Assembly
477
Re-Fitment of Clutch Assembly
479
Engine/Transmission Fixings
480

Lotus Categories

Commercial Food Equipment Watch Automobile Fryer Cookers

More Lotus Manuals

User Manuals: Lotus Elise 2001 Sports Car

Lotus Elise 2001 Service Notes (481 pages)

Table of Contents

Related Products

Lotus Categories