Lotus Evora Manuals

Lotus Evora Manuals

Manuals and User Guides for Lotus Evora. We have 1 Lotus Evora manual available for free PDF download: Service Notes

Lotus Evora Service Notes

Lotus Evora Service Notes (371 pages)

Brand: Lotus | Category: Automobile | Size: 10 MB

Table of Contents

Service Notes
1
Contents
3
Vehicle Identification Number & Engine Number
4
Engine Number
4
Model History
5
Lifting Points
6
Chassis
7
General Description
9
Chassis Straightness Check
10
Rear Subframe
11
To Remove/Refit Rear Subframe
11
Front Subframe
12
To Remove/Refit Front Subframe
12
Table of Contents
14
Bodycare & Repair
14
Lotus Composite Body Features
16
Bodycare
17
Washing
17
Accident Damage Assessment
18
Paintwork Polishing
18
Ventilation
18
Body Panel Bonding Materials
19
Applicator Bottle
19
Betaclean 3900 (A100B6008V)
20
Betabrade F1 (A120B6043V)
20
Betaclean 3300 (A120B6042V)
20
Betawipe 4000 (A082B6355V)
20
Betaprime 5404 (A082B6337V)
21
Betaprime 1707 A+B (A111B6374V)
21
Bu.1
21
Bu.3
22
- Windscreen Frame
  23
- To Replace Windscreen Frame
  23
Bu.4
23
- Body Side Panels
  24
- To Replace Body Side Panel
  24
Bu.5
24
- Rear Bulkhead
  25
- Body Fittings
  27
- Bv.7
  28
- Reservoir Access Hatch
  29
- Tailgate
  29
- Access Panel Adjustment
  29
- Tailgate Remove/Refit
  29
Bu.8
29
- 'A' Panel Removal/Replacement
  30
- 'A' Panels
  30
- Front Bumper
  31
- Front Clamshell
  31
- Front Clamshell Removal/Replacement
  31
- Rear Clamshell
  32
- Rear Clamshell Removal/Replacement
  33
- Rear Bumper
  34
- Door Mirrors
  35
- Replacement of Mirror Glass and Cover
  35
- To Remove/Refit Rear Bumper
  35
- Door Shell, Beam & Hinges
  36
- Replacement of Mirror Assembly
  36
- Bv.11
  37
  - Check Strap
    37
  - Door Weatherstrip
    37
  - Door Weatherstrip Seals
    37
  - Drop Glass Waist Seal
    37
- Bv.12
  38
  - DOOR WINDOW, Guide RAILS & LIFT MECHANISM
    38
  - Viewed from Outboard
    38
- Bv.13
  39
  - Door Glass Adjustment
    39
  - Door Glass Removal
    39
  - Guide Rail Removal
    39
  - Window Lift Mechanism
    39
- Bv.14
  40
- Door Latch Mechanism
  40
- Bv.15
  41
  - Exterior Release Handle
    41
  - Latch Mechanism
    41
  - LH Door Exterior Lock
    41
  - Windscreen Removal/Replacement
    41
- Shelf Life
  43
- To Replace Tailgate Glass
  43
- Spillage of Material
  43
- Tailgate Glass
  43
- To Replace Rear Quarter Light Glass
  44
- Cabin Rear Window
  44
- Rear Quarter Light Window
  44
- Front Suspension
  46
- General Arrangement
  47
- Geometry & Adjustments
  48
- To be Revised
  49
- Alignment
  49
- Camber Adjustment
  50
- Cambolt Effects
  50
- Wishbone Pivot Bushes & Swivel Joints
  51
- Cambolt Illustration
  51
- Castor Adjustment
  51
- Pivot Bushes
  51
- Damper Pivots
  52
- Anti-Roll Bar
  52
- Steering Swivel Joints
  52
- Suspension Disassembly/Assembly
  53
- Hub Carrier
  53
- Damper and Spring
  53
- Upper Wishbone
  53
- Front Wheel Bearings
  55
- To Replace Hub Bearing Assembly
  55
- Rear Suspension
  56
- Rear Suspension Layout
  57
- Wishbone Pivot Bushes & Spherical Joints
  61
- Upper and Lower Wishbones
  63
- Rear Wheel Bearings
  64
- Engine
  66
- General Layout
  67
- Air Cleaner Element Inspection/Replacement
  68
- Engine Oil & Filter Change
  69
- Oil Filter
  69
- Auxiliary Drive Belt
  70
- Engine Removal/Replacement
  70
- Auxiliary Belt Replacement
  70
- Engine Special Tools
  72
- Engine Repair
  72
- Engine Management
  73
- Diagnostic Trouble Code (Dtc) List
  75
- Component Function
  79
- Diagnostic Guide
  83
- Camshaft Timing Control (VVT)
  83
- Crankshaft Position–Camshaft Position Correlation Error
  84
- Intake Air Flow
  86
- Barometric Pressure
  88
- Intake Air Temperature
  89
- Engine Coolant Temperature
  91
- Sensor Connections
  91
- Sensor Characteristics
  91
- Throttle Position
  93
- O2 Sensor (Pre Catalyst)
  97
- Malfunction Criteria
  99
- Potential Failure Modes
  99
- O2 Sensor (Post Catalyst)
  100
- Fuel Control System too Lean or Rich
  103
- Fuel Injection System
  105
- Misfire
  106
- Knock Control System
  108
- Engine Speed / Position Sensors
  109
- Ignition System
  111
- Catalyst System Efficiency
  112
- Evaporative Emission Control – Leak Detection System
  114
- Evaporative Emission Control – Purge, Open / Closed Circuit
  117
- Fuel Level Sensor
  119
- Engine Cooling Fan Control
  121
- Vehicle Speed Sensor
  122
- Idle Speed Control
  123
- A/C Evaporator Temperature Sensor
  124
- Battery Voltage
  125
- Cruise Control
  126
- Variant Code Not Programmed
  129
- Crank Relay
  130
- Fuel Pump Relay
  131
- VIN Not Programmed or Incompatible – ECU/PCM
  132
- Throttle Actuator Control Range/Performance
  133
- Air Conditioning System
  134
- Variable Intake Manifold Circuit
  135
- Clutch Position Sensor Circuit
  136
- Air Intake Control Valve Circuit
  138
- Coolant Recirculation Pump
  140
- Throttle Actuator Control Motor Circuit/Open
  141
- Throttle Actuator Control Motor Circuit/Low
  141
- Throttle Actuator Control Motor Circuit/High
  141
- Throttle Actuator Control System – Forced Idle
  142
- Throttle Actuator Control System – Forced Engine Shutdown
  142
- Throttle Actuator Control System – Forced Limited Power
  143
- Throttle Actuator Control Module Processor
  143
- Throttle Actuator Control Module Performance
  144
- Pedal Position Sensor 'D' Circuit Low
  144
- Pedal Position Sensor 'D' Circuit High
  145
- Pedal Position Sensor 'E' Circuit Low
  145
- Throttle Position Sensor 'A'/'B' Voltage Correlation
  146
- Pedal Position Sensor 'E' Circuit High
  146
- Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation
  147
- Throttle Actuator Control System – High Airflow Detected
  147
- A/C Refrigerant Distribution Valve
  148
- A/C Compressor Lock Sensor Circuit
  149
- Lost Communications with TCM
  150
- Lost Communications with VDCM
  150
- Lost Communications with TPMS
  150
- Software Incompatible with VDCM
  151
- Emr.2 - Can Bus Diagnostics; Lotus Techcentre
  152
- Transmission
  153
- Gearchange Mechanism
  155
- Gearchange Cable Adjustment
  156
- Gearchange Cable Replacement
  157
- RH Driveshaft Assembly
  158
- LH Driveshaft Assembly
  158
- Drive Shafts
  158
- Driveshaft Assembly Replacement
  159
- Driveshaft C.V. Joint And/Or Gaiter Replacement
  160
- Extension Shaft Support Bearing
  160
- Transmission Removal/Replacement
  162
- Transmission Overhaul
  162
- To Separate the Engine/Transmission Assembly
  162
- Wheels & Tyres
  163
- Tyre Pressure Monitoring System (Tpms)
  164
- Wheels
  165
- TPMS Fault Codes
  165
- Wheel Bolts
  166
- Tyres
  166
- Winter Tyres & Snow Chains
  167
- Snow Chains
  167
- Punctured Tyre Emergency Inflator
  168
- Steering
  169
- Column and Rack Assembly
  170
- Power Steering Rack Operation
  171
- Power Steering Schematic (RHD Shown)
  173
- Pas Fluid Check & Refill Procedure
  175
- Steering Wheel
  175
- Fluid Level Check
  175
- To Remove Steering Wheel
  175
- Steering Wheel Alignment
  176
- Steering Column Assembly
  177
- To Remove Steering Column Assembly
  177
- Track Rod Ends & Rack Gaiters
  178
- To Refit Steering Column Assembly
  178
- Front Wheel Alignment
  178
- Steering Rack Gaiters
  179
- Track Rod Ends
  179
- Rack & Pinion Assembly Removal/Replacement
  179
- To Re-Fit/Replace Steering Rack Assembly
  180
- PAS Pump Test Procedure
  180
- To Remove/Replace Steering Rack Assembly
  180
- Pas Pump Removal & Inspection
  181
- Vane Pump Mechanism
  182
- Braking System
  183
- Tell Tale Lamps
  186
- Brakes Tell Tale
  186
- Brake Fluid Check & Change
  186
- Brake Fluid Reservoir
  187
- Renewal of Brake Fluid
  187
- Brake Bleeding Procedure
  187
- Front Brake Shown
  188
- Parking Brake Mechanism
  189
- Brake Disc Thickness
  190
- Brake Discs
  190
- Parking Brake Lever
  190
- Parking Brake Shoes
  190
- Brake Callipers
  191
- Brake Master Cylinder
  191
- Rear Disc Replacement
  191
- Vacuum Servo Unit
  192
- Brakes off
  192
- Initial Movement
  192
- Pressure Balance
  192
- Tandem Servo Section (Brakes Off)
  193
- Maximum Assistance
  193
- Operational Check
  193
- Pedal Removal
  194
- Pedal Box
  194
- To Replace Brake Servo Unit
  194
- Electro-Hydraulic Control Unit
  195
- Abs Theory of Operation
  195
- Anti-Lock Braking
  196
- Sequence of Operation
  197
- Normal Braking
  197
- Pressure Isolation (Pressure Maintain)
  198
- Pressure Reduction
  199
- Pressure Increase (Re-Apply)
  200
- Brake Release
  201
- Electro-Hydraulic Unit
  202
- To Remove Electro-Hydraulic Unit
  202
- Special Tools
  203
- Lotus Techcentre
  203
- Data Link Connector (Dlc)
  203
- Wheel Speed Sensors
  203
- ‘Lotus Techcentre’ Checking Procedures
  204
- Trouble Codes
  204
- Abbreviations & Definitions
  205
- ECU Identification
  205
- Diagnostic Trouble Codes
  206
- Engine Cooling
  208
- Thermostat Closed
  210
- Thermostat Closed Circuit (Cold Engine)
  210
- Thermostat Open Circuit (Normal Running Temperature)
  211
- Header Tank
  211
- Re-Circulation Pump
  211
- Drain/Refill Procedure
  212
- Anti‑Freeze/Corrosion Inhibitor
  212
- Radiator Fin Cleaning
  212
- Radiator & Cooling Fans
  213
- Radiator Fans
  213
- Radiator Fan & Re-Circ. Pump Control
  214
- Radiator Feed & Return Pipes
  214
- Cooling Fans Control
  214
- Heat Soak
  214
- Fuel System
  216
- Evora Fuel System Layout
  217
- Fuel Requirement & Filling
  219
- Fuel Pressure Relief Procedure
  220
- Fuel Pump/Tank Sender
  221
- To Remove/Refit Fuel Pump Assembly
  221
- Fuel Tank
  222
- Fuel Tank Removal/Refit
  222
- To Remove Pump/Sender Assembly
  223
- To Test Fuel Pump Output
  223
- Charcoal Canister
  223
- Fuel Supply Test
  223
- Electrics
  225
- Pfk 457 Vehicle Security Alarm
  226
- Vehicle Security Alarm
  226
- Transmitter Keys
  226
- Disarming the Alarm/Unlocking
  226
- Auto Re-Arm
  227
- Passive Immobilisation
  227
- Arming the Alarm/Locking the Doors
  227
- Turning off the Interior Movement Sensor
  228
- Opening the Tailgate
  228
- Manual Activation of Siren
  228
- Transmitter Key Battery Replacement
  228
- Trigger Report Back and Feature Selection
  229
- Disconnecting the Car Battery
  229
- Programming Additional Transmitters
  229
- Quick Test
  230
- Location of Alarm Components
  230
- To Open the Doors from Outside
  230
- Interior Door Lock Switch
  230
- To Open the Doors from Inside
  231
- Locking the Doors Mechanically
  231
- Inertia Switch
  231
- CDL Component Location
  231
- Switches & Instruments - Driver's Information
  234
- Ignition Switch/Steering Lock
  234
- Bulb Check
  235
- High RPM Tell Tales
  235
- Turn Tell Tale
  235
- Engine Malfunction Indicator Lamp
  236
- Scheduled Service Tell Tale
  236
- Passenger Airbag off Switch
  236
- Rear Foglamp Tell Tale
  236
- Traction Control Tell Tale
  237
- ABS Tell Tale
  237
- Brake Tell Tale
  237
- Oil Pressure Tell Tale
  237
- Instruments
  238
- Seat Belt Tell Tale
  238
- Airbag Tell Tale
  238
- Tachometer
  238
- Fuel Level Display
  239
- Ambient Air Temperature Display
  239
- Time Clock
  239
- Information Switch
  239
- Tyre Pressure Units (if TPMS Is Fitted)
  240
- Trip Recorder
  240
- Ambient Temperature Units
  240
- Coolant Temperature Display
  240
- Door/Tailgate Open Display
  241
- Lighting Switches
  241
- Sidelamp Switch
  241
- Headlamp Switch
  241
- ‘Lights On’ Warning
  242
- Rear Fog Lamp Switch (Where Fitted)
  242
- Reversing Lamp, Parking Aids and Reversing Camera
  242
- Hazard Warning Lamps Switch
  242
- Steering Column Lever Switches
  243
- Turn Indicators/Headlamp Flash/Dipswitch
  243
- Wiper Functions
  243
- Windscreen Washer Functions
  243
- Interior Lighting
  244
- Horn
  244
- Passenger Airbag Defeat (PAB) Switch
  244
- Headlamp Powerwash
  244
- Lotus Traction Control
  245
- Sport Mode (if Fitted)
  245
- Component Location & Fuse Ratings
  247
- Main Fusebox
  247
- Slot Rate Circuit
  247
- Front Relay Blocks
  248
- Integrated Control Module
  248
- Key to ICM Diagram
  249
- Rear Fusebox
  250
- Component Location
  251
- Audio Equipment
  251
- Battery Reconnection
  252
- Battery Access
  252
- Disconnecting the Battery
  252
- Battery
  252
- Wiper Mechanism
  253
- Quiescent Drain
  253
- Battery Cables
  253
- Harness Routing
  254
- To Remove the Wiper Mechanism
  254
- Headlamp Assemblies
  255
- Xenon Headlamp Assemblies
  255
- Headlamp Servicing
  255
- Headlamp Housing Removal
  255
- Headlamp Units
  256
- HID Xenon Headlamps (if Fitted)
  256
- Headlamp Beam Alignment
  256
- Bulb Replacement
  256
- Rear Lamp Cluster Bulbs
  257
- Rear Fog and Reverse Lamps
  257
- Side Repeater Lamps
  257
- Licence Plate Lamps
  257
- Circuit Diagrams
  258
- Maintenance & Lubrication
  308
- Recommended Lubricants
  309
- 'Severe Service’ Conditions
  310
- Special Operating Conditions
  311
- Additional Servicing
  311
- Pre-Delivery Inspection
  314
- Pre-Delivery Paint Mark up - Evora
  316
- Licence Plate Fitment
  317
- Air Conditioning, Heating & Ventilation
  318
- Closed Circuit
  320
- Air Conditioning - Basic Principles
  320
- Heater Circuit
  320
- Compressor
  321
- Condenser
  321
- Receiver-Drier
  321
- Expansion Valve
  321
- Evaporator
  322
- Heater/A.C. Airflow Overview
  322
- Interior Climate Controls
  323
- Distribution Control
  323
- Face Level Vents
  323
- Face Level Vents & Footwells
  324
- Footwell Vents
  324
- Footwells & Windscreen
  324
- Re-Circulation Switch
  325
- Interior Fan
  325
- Temperature Control
  325
- Windscreen
  325
- Heated Rear Screen
  326
- Pollen Filter
  326
- Engine Bay Ventilation
  326
- Cooling Fans & Re-Circulation Pump
  326
- Refrigerant Handling
  327
- Refrigerant Pipework Precautions
  327
- Refrigerant Pipework Fixing Torques
  328
- Refrigerant Pipework 'O' Rings
  328
- Refrigerant Oil
  329
- Approved Oils
  329
- Compressor Removal
  329
- Oil Quantity Adjustment Prior to Compressor Refitment
  330
- Refitting Existing Compressor
  330
- Fitting New Compressor
  330
- Compressor Fitment
  331
- To Remove Condenser
  331
- Heater/Evaporator/Fan (Hvac) Unit
  332
- To Remove HVAC Unit
  332
- Air Distribution Unit (Adu)
  333
- To Remove the Air Distribution Unit
  333
- Refrigerant Pipes
  334
- Clutch
  335
- Clutch Pedal
  337
- Hydraulic Release System
  337
- Master Cylinder
  337
- To Replace the Master Cylinder
  337
- Slave Cylinder
  338
- Hydraulic Pipe
  338
- Inspection & Replacement
  339
- Clutch Assembly
  339
- Technical Data - Engine
  340
- Technical Data - Vehicle
  344
- Interior Trim
  348
- To Remove/Refit Door Trim Panel
  351
- Door Trim Panel Components
  351
- Door Sill Trim Panel
  351
- Trim Feature Strip & Mood Lighting
  351
- Lower 'A' Post Trim Panel
  352
- Centre Console
  352
- Fascia Dash Panel
  352
- Fascia Lower Panels
  353
- Main Fascia Panel
  353
- Steering Column Shroud
  353
- REAR SEAT Backrest or Bulkhead PAD
  354
- Rear Quarter Panels
  354
- Windscreen Pillar Trim Panels
  354
- Roof Lining
  355
- Airbag System
  356
- CAN BUS Diagnostics
  359
- Safety Precautions, Shipping, Storage & Disposal
  360
- Sensor & Diagnostic Module (SDM) & Forward Crash Sensors
  360
- Inflator Module
  360
- Vehicle Scrapping Procedures
  361
- Deployed Inflator Modules
  362
- Inspections Required after an Accident
  362
- Sensor & Diagnostic Module (SDM)
  362
- Frontal Impact Sensing and Deployment
  363
- Fault Display
  363
- To Replace SDM
  364
- Energy Reserve
  364
- Supply Voltage Range
  364
- Power Supply & Grounding
  364
- Driver Airbag Module
  365
- To Replace Driver's Airbag
  365
- Rotary Connector
  366
- To Replace the Rotary Connector
  366
- Passenger Airbag Module
  367
- To Replace Passenger Airbag
  367
- Seat Belt Pre-Tensioners
  368
- Device Operation
  368
- To Replace Front Seat Belt Assembly
  369
- Safety Standard
  369
- Transportation of Belt with Pre-Tensioner
  370
- Storage of Belt with Pre-Tensioner
  370
- Disposal of Belts with Pre-Tensioner
  370
- Vehicle Disposal
  370

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