Lotus Elise (1996) manual

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Buen manual de instrucciones

Las leyes obligan al vendedor a entregarle al comprador, junto con el producto, el manual de instrucciones Lotus Elise (1996). La falta del manual o facilitar información incorrecta al consumidor constituyen una base de reclamación por no estar de acuerdo el producto con el contrato. Según la ley, está permitido adjuntar un manual de otra forma que no sea en papel, lo cual últimamente es bastante común y los fabricantes nos facilitan un manual gráfico, su versión electrónica Lotus Elise (1996) o vídeos de instrucciones para usuarios. La condición es que tenga una forma legible y entendible.

¿Qué es un manual de instrucciones?

El nombre proviene de la palabra latina “instructio”, es decir, ordenar. Por lo tanto, en un manual Lotus Elise (1996) se puede encontrar la descripción de las etapas de actuación. El propósito de un manual es enseñar, facilitar el encendido o el uso de un dispositivo o la realización de acciones concretas. Un manual de instrucciones también es una fuente de información acerca de un objeto o un servicio, es una pista.

Desafortunadamente pocos usuarios destinan su tiempo a leer manuales Lotus Elise (1996), sin embargo, un buen manual nos permite, no solo conocer una cantidad de funcionalidades adicionales del dispositivo comprado, sino también evitar la mayoría de fallos.

Entonces, ¿qué debe contener el manual de instrucciones perfecto?

Sobre todo, un manual de instrucciones Lotus Elise (1996) debe contener:
- información acerca de las especificaciones técnicas del dispositivo Lotus Elise (1996)
- nombre de fabricante y año de fabricación del dispositivo Lotus Elise (1996)
- condiciones de uso, configuración y mantenimiento del dispositivo Lotus Elise (1996)
- marcas de seguridad y certificados que confirmen su concordancia con determinadas normativas

¿Por qué no leemos los manuales de instrucciones?

Normalmente es por la falta de tiempo y seguridad acerca de las funcionalidades determinadas de los dispositivos comprados. Desafortunadamente la conexión y el encendido de Lotus Elise (1996) no es suficiente. El manual de instrucciones siempre contiene una serie de indicaciones acerca de determinadas funcionalidades, normas de seguridad, consejos de mantenimiento (incluso qué productos usar), fallos eventuales de Lotus Elise (1996) y maneras de solucionar los problemas que puedan ocurrir durante su uso. Al final, en un manual se pueden encontrar los detalles de servicio técnico Lotus en caso de que las soluciones propuestas no hayan funcionado. Actualmente gozan de éxito manuales de instrucciones en forma de animaciones interesantes o vídeo manuales que llegan al usuario mucho mejor que en forma de un folleto. Este tipo de manual ayuda a que el usuario vea el vídeo entero sin saltarse las especificaciones y las descripciones técnicas complicadas de Lotus Elise (1996), como se suele hacer teniendo una versión en papel.

¿Por qué vale la pena leer los manuales de instrucciones?

Sobre todo es en ellos donde encontraremos las respuestas acerca de la construcción, las posibilidades del dispositivo Lotus Elise (1996), el uso de determinados accesorios y una serie de informaciones que permiten aprovechar completamente sus funciones y comodidades.

Tras una compra exitosa de un equipo o un dispositivo, vale la pena dedicar un momento para familiarizarse con cada parte del manual Lotus Elise (1996). Actualmente se preparan y traducen con dedicación, para que no solo sean comprensibles para los usuarios, sino que también cumplan su función básica de información y ayuda.

Índice de manuales de instrucciones

  • Página 1

    SERVIC E NOTE S LOTU S CAR S LT D Norwich , Norfolk , NR1 4 8EZ , England . Telephone : 0.195 3 608000 Telefax : 0195 3 60830 0 Par t Numbe r A111T0327 J © Lotu s Car s Ltd . 199 6[...]

  • Página 2

    Publicatio n Par t Numbe r A111T0327 J © Lotu s Car s Ltd . Jun e 1996 . Thi s publicatio n ha s bee n designe d fo r us e b y Lotu s Dealer s familia r wit h genera l work - sho p safet y procedure s an d practices . Tak e al l appropriat e actio n t o guar d agains t injur y t o person s o r damag e t o property . Lotu s polic y i s on e o f con[...]

  • Página 3

    Lotu s Servic e Note s Introductio n CONTENT S MH 1 5US E Sectio n Technica l Dat a - Engin e TD L - Vehicl e TD M Chassi s A F Bodycar e & Repai r B M Bod y Fitting s B N Fron t Suspensio n C G Rea r Suspensio n D E Engin e (inc . Rove r publicatio n RC L 0057ENG ) E E Engin e Managemen t EM N Transmissio n (inc . Rove r publicatio n RC L 0124[...]

  • Página 4

    Lotu s Servic e Note s Introductio n VEHICL E IDENTIFICATIO N NUMBE R & ENGIN E NUMBE R Th e Vehicl e Identificatio n Numbe r (V.I.N. ) i s stampe d o n th e chassi s i n th e righ t han d rea r wheelarc h area , an d i s als o printe d o n a labe l stuc k t o th e bod y i n th e fron t service s compartment . Th e engin e numbe r i s marke d o[...]

  • Página 5

    Lotu s Servic e Note s Introductio n •9 8 M.Y . onward s Manufacture r Identifie r Cod e Vehicl e Typ e 11 1 = Elis e Chec k Digi t Engin e Typ e G = 1. 8 'K16 ' J = 1. 8 WC ' K = Spor t 16 0 Restrain t A = Activ e belt s Assembl y Plan t Mode l H = Hethe l 3 = Elis e B = Sha h 6 = 340 R Ala m 8 = Exig e / Mode l Yea r W = 199 8 X [...]

  • Página 6

    Lotu s Servic e Note s Introductio n JACKIN G POINT S Car e mus t b e take n whe n usin g a liftin g jac k o r hois t onl y t o positio n th e devic e i n on e o f th e th e area s show n i n th e illustration , wit h a suitabl e rubbe r o r timbe r pa d protectin g th e chassi s fro m surfac e damage . I f a 4-poin t lif t i s t o b e used , th e [...]

  • Página 7

    Lotu s Servic e Note s Introductio n ELIS E MODE L HISTOR Y Mode l Introduction : Jun e '9 6 VIN: T 001 7 onward s 199 7 Mode l Year : Novembe r '9 6 VIN: V 24 0 onward s N o specificatio n change . Uprate d Starte r Motor : Februar y '9 7 VIN : V68 5 Starte r moto r uprate d fro m 1. 0 k W t o 1. 4 k W an d engin e managemen t fus e[...]

  • Página 8

    Lotu s Servic e Note s Introductio n 13 5 Sport : Novembe r '9 8 VIN : X 540 1 - 5450 , 600 1 - 6035 . 13 5 bh p cylinde r head ; Clos e rati o gearbox ; Sport s exhaust ; Competitio n styl e seats ; Sport s steerin g wheel ; Drille d iro n brak e discs ; Quicksilve r pain t wit h blu e sof t top ; Headlam p covers ; Bod y graphics ; Silve r r[...]

  • Página 9

    Lotu s Servic e Note s Introductio n Spor t 160 : Februar y '0 0 SVA : VIN : Y 0060 1 t o 00650 . WVTA : VIN : Y 0651 onwards . Firs t 5 0 car s wit h Singl e Vehicl e Approval . Subsequen t car s Whol e Vehicl e Typ e Approved . Hig h per - formanc e derivative , base d o n 111 S specificatio n wit h 16 0 P S fixe d valv e timin g engine . WV[...]

  • Página 10

    Pag e 8 200 0 / 0 3[...]

  • Página 11

    Lotu s Servic e Note s Sectio n TD L TECHNICA L DAT A - ENGIN E SECTIO N TD L - M11 1 ELIS E Pag e Genera l 2 Cylinde r Hea d 2 Camshaft s & Valv e Timin g 2 Valve s 2 Valv e Guide s 3 Valv e Seat s 3 Valv e Spring s 3 Crankshaf t 3 Pisto n Ring s 3 Pisto n 3 Cylinde r Bloc k 3 Oi l Pum p 4 Coolan t Thermosta t 4 M M /fl 2 Pag e 1[...]

  • Página 12

    Lotu s Servic e Note s Sectio n TDM GENERA L Typ e designatio n - st d -111 S Configuratio n & no . o f cylinder s Capacit y Bor e Strok e Valv e actuatio n - st d - 111 S Compressio n rati o Firin g orde r Spar k plug s Spar k plu g ga p Maximu m engin e spee d Fue l syste m - st d - 111 S Fue l requiremen t Ma x powe r (88/195/EEC ) - st d -1[...]

  • Página 13

    Lotu s Servic e Note s Sectio n TD L Ste m clearanc e i n guid e - inle t - exhaus t - ne w - servic e limi t - ne w - servic e limi t Valv e clearanc e Valv e ste m fitte d heigh t - ne w - servic e limi t 0.03 3 - 0.06 3 m m 0.07 0 m m 0.03 8 - 0.07 8 m m 0.11 0 m m Hydraulicall y controlled . 38.9 3 - 39.8 4 m m 40.1 0 m m VALV E GUIDE S Insid e[...]

  • Página 14

    Lotu s Servic e Note s Sectio n TDM OI L PUM P Oute r roto r t o housin g clearanc e Inne r roto r ti p clearanc e Roto r en d floa t COOLAN T THERMOSTA T Nomina l settin g Thermosta t start s openin g Thermosta t full y ope n 0.2 8 - 0.3 6 m m 0.0 5 - 0.1 3 m m 0.0 2 - 0.0 6 m m 85-91 ' 88° C 100° C Pag e 17[...]

  • Página 15

    Lotu s Servic e Note s Sectio n TDL TECHNICA L DAT A - VEHICL E SECTIO N TD M - M11 1 ELIS E Pgg e Dimension s 2 Capacitie s 2 Tyre s 2 Winte r Tyre s 3 Wheel s 3 Fron t Suspensio n 3 Rea r Suspensio n 4 Electrica l 4 Transmissio n 4 Clutc h 5 Brake s 5 Steerin g 5 Fue l Consumptio n 5 2000/8 2 Pag e 1[...]

  • Página 16

    Lotu s Servic e Note s Sectio n TD M DIMENSION S Overal l lengt h - st d Overal l widt h 111 S exc . mirror s st d 111 S - inc . mirror s Overal l heigh t (a t ker b weight ) Wheelbas e Trac k - fron t - rea r - st d - 111 S Groun d clearanc e Fron t overhan g Rea r overhan g - st d - 111 S CAPACITIE S Engin e oi l - dr y - refil l inc . filte r Hi[...]

  • Página 17

    Lotu s Servic e Note s Sectio n TDL Note : a ) Th e U.K . buil t tyr e wa s introduce d o n productio n a t VIN : V 170 0 (approx) . b ) Italia n an d U.K . variation s o f rea r tyr e shoul d no t b e mixe d o n th e sam e axle . c ) Th e DO T cod e i s moulde d o n th e outsid e wall , wit h onl y th e las t numbe r grou p relevan t t o thi s iss[...]

  • Página 18

    Lotu s Servic e Note s Sectio n TD M REA R SUSPENSIO N Typ e Geometr y chec k rid e heigh t ( 2 persons , 1 / i tan k fuel ) - fron t - rea r Alignmen t Cambe r For Motorsport suspension settings: see Section XA ELECTRICA L Independent . Uppe r an d lowe r wishbone ; co - axia l coi l spring/telescopi c damper . 14 0 m m belo w fron t en d o f chas[...]

  • Página 19

    Lotu s Servic e Note s Sectio n TDL CLUTC H Typ e Frictio n plat e diamete r Diaphrag m finge r clearanc e Diaphrag m finge r heigh t - ne w - servic e limi t Frictio n plat e thicknes s - ne w - servic e limi t Rive t dept h - ne w - servic e limi t Frictio n plat e run-ou t - ne w - servic e limi t Pressur e plat e war p - servic e limi t BRAKE S[...]

  • Página 20

    Lotu s Servic e Note s Sectio n TDL CHASSI S SECTIO N A F - M11 1 Sub-Sectio n Paq e Genera l Descriptio n AF. 1 3 Chassi s Straightnes s Chec k AF. 2 4 Rea r Subfram e & Longeron s AF. 3 5 200 0 /0 2 Pag e 1[...]

  • Página 21

    Pag e 2[...]

  • Página 22

    Lotu s Servic e Note s Sectio n TDL AF. 1 - GENERA L DESCRIPTIO N Th e chassi s fram e o f th e Lotu s typ e M11 1 Elis e i s constructe d primarily fro m aluminiu m allo y extrusion s an d forme d allo y sheet , wit h th e variou s section s bonde d togethe r usin g a n epox y adhesiv e wit h secondar y drive-i n fasteners . Th e basi c chassi s u[...]

  • Página 23

    Lotu s Servic e Note s Sectio n TDM AF. 2 - CHASSI S STRAIGHTNES S CHEC K I n th e absenc e o f visua l damage , th e chassi s ma y b e checke d fo r twis t o r distortio n b y utilisin g th e toolin g hole s i n th e undersid e o f th e mai n sid e rails . I f compute r processe d lase r measurin g equipmen t i s no t available , manua l check s c[...]

  • Página 24

    Lotu s Servic e Note s Sectio n TDL AF. 3 - REA R SUBFRAM E & LONGERON S Th e rea r end s o f th e chassi s siderail s ar e linke d b y a fabricate d shee t stee l subfram e whic h provide s rea r suspensio n mountings , an d a n ancho r poin t fo r th e engin e rea r stead y bar . A t eac h side , a n extrude d bo x sectio n 'longeron &ap[...]

  • Página 25

    Lotu s Servic e Note s Sectio n TDM Hoo k th e longero n ove r th e edg e o f th e subfram e an d ont o th e adhesiv e an d slid e full y forwar d unti l aligne d wit h th e rive t hole s an d rol l ove r ba r brac e fixin g hol e i n th e tappin g block . I f a n aluminiu m boo t floo r i s use d (i.e . pr e 'boo t box') , fi t th e floo[...]

  • Página 26

    • BODYCAR E & REPAI R SECTIO N B M - M11 1 ELIS E Sub-Sectio n Pag e Genera l Descriptio n BM. 1 3 Lotu s Composit e Bod y Feature s BM. 2 3 Bodycar e BM. 3 3 Acciden t Damag e Assessmen t BM. 4 5 Bod y Pane l Bondin g Material s BM. 5 6 Replacemen t o f Bonded-O n Panel s - Genera l BM. 6 9 Fron t Cras h Structur e BM. 7 1 0 Windscree n Fram[...]

  • Página 27

    Lotu s Servic e Note s Sectio n TDM Principa l Bod y Component s Windscreen frame/scuttle RH door shell Front compartment lid Engine cover lid (aluminium alloy) Crash structure Chassis structure (aluminium alloy) iizz l Pag e 17[...]

  • Página 28

    Lotu s Servic e Note s Sectio n TDM BM. 1 - GENERA L DESCRIPTIO N Th e bod y panel s o f th e Lotu s Elis e ar e constructe d o f composit e materials , wit h th e externa l panel s no t bein g require d t o contribut e t o chassi s rigidity . Th e panel s ar e attache d t o th e aluminiu m chassi s and/o r othe r bod y panel s eithe r b y elastome[...]

  • Página 29

    Lotu s Servic e Note s Sectio n TDM Atmospheri c contaminants ; dust , soot , ash , an d acidi c o r alkalin e aeroso l mis t ca n chemicall y attac k paint . Abrasion ; blowin g san d an d dust , o r a dirt y washin g cloth . Tre e sa p an d insec t fluids ; ca n for m a water-insolubl e polyme r tha t adhere s t o th e paint . Bir d droppings ; h[...]

  • Página 30

    Lotu s Servic e Note s Sectio n TDM fro m wheel s an d tyres . Upholster y Cleanin g Cloth Upholstery: Norma l cleanin g consist s o f a n occasiona l ligh t wip e ove r wit h a clot h dampene d i n a mil d soa p an d wate r solution ; i t i s importan t tha t th e clot h i s onl y dampened , no t soaked . Alternatively , a proprietar y upholster y[...]

  • Página 31

    Lotu s Servic e Note s Sectio n TDM BM. 5 - BOD Y PANE L BONDIN G MATERIAL S Th e material s use d fo r bondin g th e bod y panel s ar e manufacture d b y Gurit-Essex , an d i n orde r t o main - tai n th e structura l integrit y o f th e vehicle , an d i n th e cas e o f th e fron t cras h structure , th e safety , i t i s mos t importan t t o us [...]

  • Página 32

    • - Pus h th e applicato r hea d ont o th e bottle , an d fi t th e fel t pad . - We t ou t th e fel t pa n b y invertin g th e applicato r bottl e an d gentl y squeezin g th e sides . - Wip e th e pa d ove r th e substrat e surfac e usin g minima l pressur e t o we t th e surface . - Immediatel y wip e of f th e activated/cleane d surfac e usin [...]

  • Página 33

    Lotu s Servic e Note s Sectio n TDM dispers e th e soli d conten t o f th e materia l int o suspension . - Pou r th e prime r int o th e applicato r bottl e an d immediatel y replac e th e gree n cap . - We t ou t th e fel t pa n b y invertin g th e applicato r bottl e an d gentl y squeezin g th e sides . - Wip e th e pa d ove r th e activated/clea[...]

  • Página 34

    Lotu s Servic e Note s Sectio n TDM © Air gun Betaseal cartridge fbj43 l BM. 6 - REPLACEMEN T O F BONDED-O N PANEL S - GENERA L Bonde d bod y panel s ar e secure d usin g th e Gurit-Esse x product s 'Betaseal ' o r 'Betamate' , whic h ar e flexibl e polyurethan e adhesive s whic h mus t b e cu t i n orde r fo r a pane l t o b e[...]

  • Página 35

    Lotu s Servic e Note s Sectio n TDM Operating handle Compressed air inlet Vibrating cutting blade I t i s no t generall y practica l t o remov e a bonde d pane l fo r late r refitment , suc h tha t whe n necessary , th e pane l ca n b e cu t awa y fo r bette r acces s t o th e bonde d joint . I t i s no t necessar y t o remov e al l trace s o f s[...]

  • Página 36

    T o remov e th e structure : Remov e th e fron t clamshel l (se e sub-sectio n BN.4) . Remov e th e fron t undershiel d b y releasin g th e thre e screw s securin g eac h lowe r sid e o f th e structur e t o th e shield , an d th e thre e screw s securin g th e shiel d t o th e fron t lowe r edg e o f th e chassis . Drai n th e coolan t an d remov [...]

  • Página 37

    Lotu s Servic e Note s Sectio n TDM Appl y a bea d o f Betaseal/mat e adhesiv e (se e sub-sectio n BM.5 ) t o th e bondin g surfac e i n th e manne r shown . Fi t th e structur e t o th e chassi s an d pres s int o positio n t o sprea d th e adhesive . Us e severa l clamp s aroun d th e join t flang e t o retai n th e structur e unti l th e adhesiv[...]

  • Página 38

    Lotu s Servic e Note s Sectio n TDM Th e shap e o f th e fram e i s critica l t o th e windscree n fit , an d structura l repair s t o th e fram e itsel f ar e no t recommended . I t i s no t generall y economi c t o attemp t t o remov e th e windscree n fram e intac t fo r refitment , a s th e elastomeri c adhesiv e require s cuttin g wit h recipr[...]

  • Página 39

    Lotu s Servic e Note s Sectio n TDM 9 . I f th e das h baffl e pane l i s damage d beyon d 'i n situ 1 repair , th e pane l mus t b e remove d b y drillin g ou t th e rivet s an d cuttin g th e adhesiv e bea d betwee n th e baffl e an d th e chassis , an d betwee n th e baffl e an d sil l panels . Th e clutc h pipe , mai n batter y lea d an d [...]

  • Página 40

    Lotu s Servic e Note s Sectio n TDM 540 4 (se e sub-sectio n BM.5) . - Appl y a bea d o f Betaseal/mat e adhesiv e (se e sub-sectio n BM.5 ) t o th e windscreen fram e flange , an d fi t th e fram e pane l int o position . 15 . Locat e th e to p o f th e windscreen fram e b y fittin g th e can t rail s int o position , an d secur e th e fram e suc [...]

  • Página 41

    Lotu s Servic e Note s Sectio n TDM 16 . Pres s ove r eac h par t o f th e windscree n fram e pane l join t t o ensur e sufficien t sprea d o f th e adhesive , an d us e clamp s a s necessar y t o retai n th e fram e whils t th e adhesiv e cures . I f necessar y us e a spatul a t o smoot h ou t o r remov e an y exces s o r extrude d adhesive . 17 .[...]

  • Página 42

    Lotu s Servic e Note s Sectio n TDM Bonding path Chassis rail upper & lower slots Button head fixing (if fitted) Sill panel 7 . Befor e preparin g th e surface s fo r bonding , ensur e tha t th e necessar y pipe s an d cable s ar e fitte d t o th e chassi s sid e rails : R H side : - heate r fee d pip e - a.c . fee d an d retur n pipe s (i f fi[...]

  • Página 43

    Lotu s Servic e Note s Sectio n TDM BM.1 0 - REA R BULKHEA D & CAPPIN G RAI L Th e rea r bulkhea d an d capping rai l ar e bonde d t o th e to p surfac e o f th e rea r chassis , an d t o th e rea r end s o f eac h sil l panel . Remova l o r replacemen t o f thes e panel s require s tha t a t leas t on e o f th e sill s b e removed . Whe n fitt[...]

  • Página 44

    Lotu s Servic e Note s Sectio n TDM BOD Y FITTING S SECTIO N B N - M11 1 ELIS E Sub-Sectio n Pag e Sof t To p Roo f BN. 1 2 Fron t Bonne t BN. 2 4 Engin e Cove r Li d BN. 3 5 Fron t Clamshel l BN. 4 7 Rea r Clamshel l BN. 5 8 Doo r Mirror s BN. 6 1 0 Doo r Bea m & Hing e BN. 7 1 2 Doo r Shel l Assembl y BN. 8 1 3 Doo r Glass , Guid e Channel s [...]

  • Página 45

    Lotu s Servic e Note s Sectio n TDM BN. 1 - SOF T TO P ROO F Concep t Th e Lotu s Elis e ha s bee n designe d t o exploi t th e pleasure s o f ope n to p motoring , th e bette r t o enjo y exposure t o th e natura l environment , unencumbere d b y th e restriction s an d confinemen t bestowe d b y a cock - pi t roof . I n orde r t o provid e som e [...]

  • Página 46

    Lotu s Servic e Note s Sectio n TDM 3 . La y th e sof t to p i n position , an d hoo k th e whol e lengt h o f th e li p o n th e fron t edg e o f th e roo f beneat h th e retainin g stri p o n th e windscree n heade r rail . Centralis e th e roo f b y wrappin g th e side s o f th e sof t to p aroun d th e sid e rails , an d clippin g th e thre e p[...]

  • Página 47

    Lotu s Servic e Note s Sectio n TDM 4 . Uncli p th e thre e pres s stud s securin g th e roo f t o eac h siderail , an d pul l th e fron t edg e o f th e roo f forward s t o releas e fro m th e heade r rai l retainin g strip . Lif t of f th e roo f fabric , la y upsid e down , an d fol d ove r eac h sid e toward s th e centre . Folding roof fabric [...]

  • Página 48

    I clampe d t o th e bonne t reinforcin g ri b wit h a tappin g plat e an d locknut , an d a latc h slide r plat e mounte d o n a n extensio n t o th e wipe r moto r bracket , itsel f fixe d t o th e scuttle . A bowde n cabl e connect s t o th e slide r plat e b y a clam p screw , an d terminate s i n a verticall y mounte d releas e handl e i n th e[...]

  • Página 49

    Lotu s Servic e Note s Sectio n TDM reinforcemen t channe l i s bonde d t o th e fron t undersid e o f th e panel , an d incorporate s thre e M 6 tappe d bobbin s fo r th e hing e blad e attachment , an d a composit e plint h i s provide d a t th e rea r fo r th e latc h strike r pin . Engine lid release handle Latc h Mechanis m Th e singl e latc h[...]

  • Página 50

    BN. 4 - FRON T CLAMSHEL L Th e fron t clamshel l i s a on e piec e composit e bod y mouldin g incorporatin g bot h fron t wings , th e fron t bonne t aperture , radiato r ai r intak e an d headlam p housings . Th e clamshel l i s secure d t o th e chassi s an d othe r bod y panel s vi a threade d fastener s fo r eas e o f remova l an d t o facilita[...]

  • Página 51

    Lotu s Servic e Note s Sectio n TDM Front Clamshell Fixings Radiator duct Windscreen buttress Front undertray 'A'post top Sill front 'A'post bottom 8 . Refi t th e clamshel l i n revers e orde r t o removal , takin g car e t o retai n an y space r washer s i n thei r origina l positions . BN. 5 - REA R CLAMSHEL L Th e rea r clam[...]

  • Página 52

    Lotu s Servic e Note s Sectio n TDM Edging strip Fixing to rear longeron Fixing to shear plate 4 . Disconnec t th e bowde n cabl e fro m th e engin e li d latc h plate , an d releas e uncli p fro m it s retainin g clips . 5 . Fro m insid e eac h wheelarch , remov e th e thre e fixing s securin g th e shea r plat e t o th e longeron . 6 . Remov e th[...]

  • Página 53

    Lotu s Servic e Note s Sectio n TDM Rear Clamshell Fixings Clamshell gutter No. plate recess Upper 'B' post fixing Lower 'B' post fixings 13 . Releas e th e tw o fixing s securin g th e fron t o f th e clamshel l li d gutte r t o th e rea r bulkhea d panel , an d th e singl e scre w eac h sid e fixin g th e gutte r t o th e boo [...]

  • Página 54

    Lotu s Servic e Note s Sectio n TDM T o remov e a glass , pul l bac k th e boo t betwee n mirro r an d plinth , an d carefull y pris e th e inboar d edg e o f th e mirro r surroun d fro m it s retainin g clips . Workin g aroun d th e mirro r periphery , continu e t o pris e th e surroun d fro m th e housin g takin g car e no t t o damag e th e pain[...]

  • Página 55

    Lotu s Servic e Note s Sectio n TDM BN. 7 - DOO R BEA M & HING E Th e doo r shel l i s bolte d t o a hollo w sectio n extrude d aluminiu m allo y doo r beam , hinge d a t th e fron t en d t o th e "B " post , an d carryin g th e doo r latc h mechanism , vi a a bracket , a t it s rea r end . Th e fron t en d o f th e doo r bea m i s we[...]

  • Página 56

    Lotu s Servic e Note s Sectio n TDL Th e doo r bea m extensio n als o incorpo - rate s a chec k flang e whic h abut s agains t a rubbe r stri p o n th e hing e bracke t t o limi t doo r openin g angle . A sprin g stee l plat e fixe d t o th e front o f th e hing e bracke t i s designe d t o engag e aroun d th e profile d edg e o f th e doo r bea m [...]

  • Página 57

    Lotu s Servic e Note s Sectio n B N bea m t o th e extensio n bracket . Remov e th e bolts , notin g an y space r washer s use d o n th e uppe r bol t betwee n th e glas s rea r guid e channe l fixin g bracke t an d th e doo r beam , an d withdra w th e doo r assembl y of f th e beam . Not e tha t i t i s necessar y t o remov e th e dro p glas s in[...]

  • Página 58

    Lotu s Servic e Note s Sectio n TDL Lift channel Door glass Lift mechanism Reaction channel Re-shim if necessary Move sideways to adjust lean Move reaction channel to adjust front/rear height Top fixing behind felt insert Move fore/aft to adjust pinch Primary scissor arm pivot Move sideways to adjust lean 193 8 /O t Pag e 1 5[...]

  • Página 59

    Lotu s Servic e Note s Sectio n B N Doo r Glas s Adjustmen t T o adjust th e doo r glas s fo r optimu m weathe r sealin g an d eas e o f operation : 1 . Remov e th e windo w winde r handl e an d doo r tri m panel . Chec k tha t th e to p en d o f th e toothe d secto r i s fitte d wit h a n eccentri c stop . I f no t s o fitted , dril l a n M 6 clea[...]

  • Página 60

    3 . Appl y 'Krytox ' P.F.P.E . lubricatin g flui d (A082V6239S ) t o th e windo w guid e channel s an d weatherstrip s t o reduc e stiction , judde r an d operatin g loads . 4 . Wit h th e windo w full y raised , chec k th e pressur e o f th e fron t an d rea r glas s edge s agains t th e 'A ' an d "B " pos t seals . T[...]

  • Página 61

    Lotu s Servic e Note s Blank page Sectio n B N Page 16 b 199 8 / 0 1[...]

  • Página 62

    Lotu s Servic e Note s Sectio n TDL To replace door window glass 1 . Remov e th e tri m pane l aroun d th e interio r releas e handle: Remov e th e tw o screw s i n th e fron t edg e o f th e finisher , an d unhoo k th e finishe r fro m th e handl e an d doo r shell . 2 . Releas e th e thre e screw s securin g th e interio r releas e handle , an d [...]

  • Página 63

    Chec k tha t a meta l gauz e frictio n washe r i s fitte d betwee n th e eccentri c sto p an d th e toothe d secto r befor e checkin g th e glas s position : Erec t th e sof t to p roo f an d rais e th e doo r glas s t o asses s th e fi t o f th e glas s agains t th e roo f an d 'A / B ' pos t seals . I f necessary , adjus t th e eccentri[...]

  • Página 64

    Lotu s Servic e Note s Sectio n TDM Th e rea r guid e channe l i s secure d b y tw o screw s throug h th e botto m fac e o f th e doo r shel l int o captiv e sprin g stee l nut s o n th e chan - ne l botto m flanges , an d b y a bracke t a t th e to p en d fixe d b y th e doo r bea m to p rea r fixin g bolt . Th e channe l mus t b e positione d t o[...]

  • Página 65

    Lotu s Servic e Note s Sectio n TDM T o fi t a ne w oute r seal : 1 . Compar e th e ne w an d ol d seals , an d i f necessary , cu t additiona l slot s i n th e ne w sea l t o allo w i t t o b e forme d t o th e profil e o f th e doo r to p surface . Chamfe r th e lowe r rea r corne r t o allo w th e sea l t o fi t correctl y i n th e door . 2 . Cl[...]

  • Página 66

    Lotu s Servic e Note s Sectio n TDM Inser t th e buffe r int o th e rea r en d o f th e weatherstri p b y threadin g a stif f wir e dow n th e centr e o f th e seal , vi a a n entr y hol e throug h th e rea r fac e o f th e sea l approximatel y 2 5 m m belo w th e latc h strike r pin . Attac h th e buffe r t o th e wire , an d dra w th e buffe r th[...]

  • Página 67

    Lotu s Servic e Note s Sectio n TDM BN.1 1 - DOO R LATC H MECHANIS M Th e doo r latc h mechanis m i s fitte d insid e th e rea r fac e o f th e door , whic h i s reinforce d b y a stee l plat e bonde d t o th e glas s fibr e composit e doo r shell . Th e latc h engage s wit h a strike r pi n whic h passe s throug h th e composit e sill/'B &apo[...]

  • Página 68

    Lotu s Servic e Note s Sectio n TDM To replace the exterior release button Remov e th e acces s dis c fro m th e rea r fac e o f th e door , an d th e ro d acces s gromme t lowe r down . Releas e th e tw o screw s secur - in g th e loc k assembl y an d angl e bracke t t o th e tappin g plat e bonde d i n th e doo r shell . Uncli p th e lin k ro d f[...]

  • Página 69

    Lotu s Servic e Note s Sectio n TDM T o remov e th e doo r bea m extensio n bracket : 1 . Remov e th e tri m pane l aroun d th e interio r releas e handle : Remov e th e tw o screw s i n th e fron t edg e o f th e finisher , an d unhoo k th e finishe r fro m th e handl e an d doo r shell . 2 . Releas e th e thre e screw s securin g th e interio r r[...]

  • Página 70

    Lotu s Servic e Note s Sectio n TDM Th e instrumen t cluste r i s mounted , vi a a combinatio n o f brackets , of f th e steerin g colum n t o scuttl e mountin g bolts , wit h th e instrumen t cow l mounte d ont o th e to p o f th e cluster . Th e das h structur e principall y consist s o f thre e aluminiu m allo y extrusions , upper , centr e an d[...]

  • Página 71

    T o Dismantl e Das h Panel s 1 . Releas e th e fou r screw s securin g th e steerin g colum n shrou d uppe r section , turnin g th e steerin g whee l a s necessar y t o permi t access . 2 . Pul l ou t th e gromme t fro m aroun d th e ignitio n switch , an d remov e th e thre e screw s securin g th e lowe r shrou d t o th e column . 3 . Squeez e th [...]

  • Página 72

    BN.1 3 - WINDSCREE N Th e laminate d windscree n i s bonde d t o th e composit e fram e usin g Betasea l flexibl e polyurethan e adhe - sive , an d use s a rubbe r finishe r stri p aroun d it s to p an d sid e edges . Remova l o f th e scree n require s tha t th e adhesiv e i s cu t usin g a suitabl e specialis t tool , wit h acces s t o th e scree[...]

  • Página 73

    Lotu s Servic e Note s Sectio n TDM 4 . Remov e ol d adhesiv e fro m th e windscree n fram e sufficientl y t o leav e a consisten t an d fla t surfac e fo r th e ne w bond . 5 . La y th e ne w windscree n (suitabl y supported ) o n a protecte d surface , insid e uppermost , an d clea n th e whol e o f th e insid e o f th e windscree n wit h a 50 % [...]

  • Página 74

    Lotu s Servic e Note s Sectio n TDM 11 . Cu t thre e 4 m m space r block s fro m th e materia l supplied , an d positio n i n th e insid e edg e o f th e adhesiv e bea d runnin g alon g th e botto m o f th e glass . Thes e spacer s ar e use d t o contro l th e fitte d heigh t o f th e glass , an d th e wipe r ar m clearance . 12 . Usin g suctio n h[...]

  • Página 75

    Lotu s Servic e Note s Sectio n TDM Shel f lif e a ) Betasea l prime r ha s a usefu l lif e o f onl y abou t 2 4 hr s afte r i t ha s bee n expose d t o th e air , afte r whic h i t start s t o becom e spongy . I f th e materia l i s spongy , D O NO T USE . Alway s us e glas s prime r immediatel y o n opening , an d replac e th e li d afte r use . [...]

  • Página 76

    • 1 . Dr y fi t th e R H moulde d carrie r an d allo y tongu e strip , usin g a 1 2 m m diamete r dowe l i n th e can t rai l spigo t hole , an d alignin g th e rea r edg e o f th e carrie r wit h th e heade r rai l edge . Dril l a 2. 4 m m diamete r pilo t hol e a t th e fixin g poin t b y th e can t rai l location , an d a t fou r o f th e head[...]

  • Página 77

    Lotu s Servic e Note s Sectio n TDM Dash Panel RHD Dash end LHD Dash top to plastic insert jointline |b268 l BN.1 6 - REA R BOO T BULKHEA D T o creat e a protectiv e wal l an d t o provid e a mountin g fo r th e optiona l rea r boo t ba g an d lid , a n allo y bulkhea d i s fitte d betwee n th e engin e an d th e rea r luggag e compartment . A bulk[...]

  • Página 78

    Lotu s Servic e Note s Sectio n TDM 1 . I n orde r t o inhibi t rattles , stic k a lengt h o f foa m rubbe r stri p betwee n th e fixin g point s o n th e turne d u p edg e o f th e rea r floor . 2 . Manoeuvr e th e bulkhea d int o positio n an d mar k th e R H flang e o f th e bulkhea d agains t th e clamshel l sidewal k Stic k thre e length s o f[...]

  • Página 79

    Lotu s Servic e Note s Sectio n DE FRON T SUSPENSIO N SECTIO N C G - M11 1 ELIS E Genera l Descriptio n Geometr y & Adjustment s Anti-Rol l Ba r Suspensio n Disassembly/Assembl y Fron t Whee l Bearing s Sub-Sectio n Paq e CG. 1 3 CG. 2 3 CG. 3 6 CG. 4 8 CG. 5 1 0 199 8 / 0 2 Pag e 1[...]

  • Página 80

    Lotu s Servic e Note s Sectio n DE GENERAL LAYOUT Spring/damper unit Top wishbone Late type anti-roll bar mounting Anti-roll bar Bottom wishbone Hub carrier Steering tie rod Upper swivel Track rod end Steering arm Wheel hub Lower steering swivel joint m i Pag e 2 199 8 / 0 2[...]

  • Página 81

    Lotu s Servic e Note s Sectio n DE CG. 1 - GENERA L DESCRIPTIO N Th e full y independen t fron t suspensio n comprises , o n eac h sid e o f th e car , uppe r an d lower , fabricate d tubula r stee l wishbones , wit h a concentri c coi l spring/telescopi c dampe r uni t pickin g u p o n th e outboar d en d o f th e lowe r wishbone . A n extrude d a[...]

  • Página 82

    Alignmen t i s measure d eithe r b y th e angl e a whee l make s wit h th e vehicl e centr e line , o r th e differenc e i n dimensio n betwee n th e whee l ri m t o whee l ri m measuremen t a t th e fron t an d rea r o f th e whee l a t hu b centr e height . Th e wheel s ar e sai d t o 'toe-in ' whe n th e whee l path s converg e ahea d [...]

  • Página 83

    Lotu s Servic e Note s Sectio n DE Th e earl y typ e use s a spli t Nylo n bus h secure d t o th e chassi s vi a th e lowe r wishbon e fron t pivo t bol t an d space r tube , wit h a secondar y M 5 bol t clampin g th e tw o halve s o f th e bus h belo w th e bar . Washer s welde d t o th e anti-rol l ba r bea r agains t th e oute r side s o f th e [...]

  • Página 84

    Lotu s Servic e Note s Sectio n DE Car s buil t fro m VI N W 303 9 (Marc h '98 ) us e bonde d rubbe r typ e pivo t bushe s an d allo y clam p bracket s t o secur e th e re-shape d anti-rol l ba r t o th e chassi s fron t face . Washer s welde d t o th e ba r bea r agains t th e inne r side s o f th e bushe s t o provid e latera l location . Ca[...]

  • Página 85

    Lotu s Servic e Note s Sectio n DE 2 . Remov e th e tw o bolt s securin g th e brak e calipe r t o th e hu b carrier , releas e th e flexibl e hos e fro m th e to p wishbone , an d suppor t th e calipe r asid e withou t strainin g th e brak e hose . Remov e th e brak e disc . 3 . Remov e th e nu t securin g th e trac k ro d en d int o th e steerin [...]

  • Página 86

    Lotu s Servic e Note s Sectio n DE - Tak e car e t o refi t th e origina l cambe r adjustmen t shimpack , an d distribut e th e shim s a s note d o n re - moval . - Lubricat e th e end s o f th e dampe r to p ey e bus h wit h rubbe r grease . - Pres s th e brak e peda l t o repositio n th e pad s befor e drivin g th e car . 15 . Th e Servic e Sched[...]

  • Página 87

    Lotu s Servic e Note s Sectio n DE Thrus t Washer , inne r A111C0118 F 2 Dus t Shield , fron t whee l bearin g B111C0076 F 2 Washer , M 16x30x 2 A111W4171 F 2 Th e M1 6 clam p bol t se t i s a direc t replacemen t fo r th e M1 2 set , an d i t i s recommende d tha t a t th e tim e o f fitting , th e hu b i s remove d fro m th e bearin g an d th e c[...]

  • Página 88

    Lotu s Servic e Note s Sectio n DE Tighte n th e hu b clam p bolt/nut : M12 ; 7 7 N m M16 ; 21 0 N m 8 . Re-assembl e th e suspensio n i n revers e orde r t o dis-assembly , referrin g als o t o sub-sectio n CG.4 . Pum p th e brak e peda l t o repositio n th e pad s befor e drivin g th e car . Pag e 1 2 199 8 / 02[...]

  • Página 89

    Lotu s Servic e Note s REA R SUSPENSIO N SECTIO N D E - M11 1 ELIS E Genera l Descriptio n Geometr y & Adjustment s Suspensio n Disassembly/Assembl y Rea r Toe-Lin k Fixing s Rea r Whee l Bearing s Whee l Spee d Senso r Barre l Shape d Roa d Spring s Sectio n D E Sub-Sectio n I 3 ag e DE. 1 3 DE. 2 3 DE. 3 5 DE. 4 8 DE. 5 1 0 DE. 6 1 2 DE. 7 1 [...]

  • Página 90

    Lotu s Servic e Note s Sectio n D E Damper clevis Upper ball joint Damper Top wishbone Rear subframe Lower wishbone Driveshaft Toe control link Road spring Lower ball joint o u Pag e 2 199 8 / 0 3[...]

  • Página 91

    Lotu s Servic e Note s Sectio n D E DE. 1 - GENERA L DESCRIPTIO N Th e full y independen t rea r suspensio n comprises , o n eac h sid e o f th e car , uppe r an d lowe r tubula r stee l wishbones , a to e contro l link , an d a concentri c coi l spring/telescopi c dampe r uni t pickin g u p o n th e outboar d en d o f th e lowe r wishbone . A n ex[...]

  • Página 92

    Lotu s Servic e Note s Sectio n D E A • FRONT fd2i 1 Measur e th e distanc e fro m th e ba r t o th e ri m o f th e whee l concerne d a t th e fron t an d rea r o f th e centr e lin e o f th e whee l (Di , D2) . I f th e fron t dimension , D1 , i s greate r tha n th e rea r dimension , D2 , th e whee l ha s TOE - IN . I f th e rea r dimensio n i [...]

  • Página 93

    Th e primar y purpos e o f cambe r i s t o achiev e th e maximu m efficienc y o f th e tyr e unde r cornerin g load s an d bod y roll , wit h th e specificatio n closel y allie d t o a particula r wheel/tyr e combination . Th e cambe r angl e change s wit h suspensio n travel , becomin g mor e negativ e o n bump , an d shoul d b e measure d onl y a[...]

  • Página 94

    Lotu s Servic e Note s Sectio n D E CAUTION : D o NO T attemp t t o remov e th e inboar d C.V . join t fro m th e transmissio n b y pullin g o n th e driveshaft . Thi s actio n wil l caus e th e join t t o becom e disassemble d an d ma y entai l replacemen t o f th e joint . Th e component s o f th e inboar d plungin g join t ar e hel d i n positio[...]

  • Página 95

    Lotu s Servic e Note s Sectio n D E Lowe r wishbon e rea r pivo t - inser t a singl e 30m m lon g bus h fro m th e fron t en d o f th e eye . Lowe r wishbon e fron t pivo t - inser t a 16m m lon g bus h int o eac h en d o f th e fron t eye . Front Divot RtarpjvQt ' FRONT Pivot mounting bracket m H E— j Weldnut Short pivot bushes Plastic Rear[...]

  • Página 96

    Lotu s Servic e Note s Sectio n D E i s importan t t o appreciat e tha t i f th e bol t i s disturbed , th e lockin g compoun d mus t b e re-applied . Th e followin g procedur e shoul d b e adopte d fo r al l suc h fixings : - Chec k th e torqu e o f th e fixing . - I f th e specifie d torqu e i s attaine d withou t th e fixin g bein g disturbe d ([...]

  • Página 97

    Lotu s Servic e Note s Sectio n D E Assembl y procedur e - toe-lin k outboar d fixin g (earl y typ e joint) : 1 . Us e a proprietar y degrease r (e.g . Silkolen e Contac t Cleaner ) t o degreas e th e femal e threa d i n th e bal l joint , checkin g tha t th e botto m o f th e hol e i s no t restricte d b y compacte d ol d adhesive , limitin g th e[...]

  • Página 98

    Lotu s Servic e Note s Sectio n D E 5 . Appl y Permabon d A13 4 t o th e whol e o f th e bol t threa d fro m ti p t o shank . (Applyin g threadloc k befor e insertio n o f th e bol t ma y glu e th e bol t int o th e carrier ) 9 . Threa d th e bol t int o th e bal l join t an d torqu e tighte n t o 4 5 Nm . sb1 5 Assembl y procedur e - toe-lin k inb[...]

  • Página 99

    Lotu s Servic e Note s Sectio n D E Assembl y procedur e - toe-lin k inboar d fixin g ('integra l stud ' typ e joint) : Thoroughl y clea n th e stu d befor e fittin g throug h th e chassi s subfram e an d wishbon e rea r bush . Fi t th e plai n washe r an d a ne w Nylo c nut , an d torqu e tighte n t o 4 5 N m onl y wit h th e ca r a t ri[...]

  • Página 100

    6 . Us e a pulle r too l i f necessar y t o extrac t th e outboar d driveshaf t fro m th e hub . 7 . Remov e th e fou r screw s retainin g th e lowe r bal l join t plint h t o th e hu b carrier , an d withdra w th e hu b carrie r assembl y t o a bench . 8 . Us e a hydrauli c pres s t o remov e th e hu b fro m th e bearing , an d i f necessary , us [...]

  • Página 101

    Lotu s Servic e Note s Sectio n D E DE. 6 - WHEE L SPEE D SENSO R Th e whee l spee d senso r i s use d t o provid e a roa d spee d signa l t o th e speedometer , an d i s mounte d o n a bracke t fixe d t o th e lef t han d rea r hu b carrier . Th e senso r i s easil y damaged , an d i f a driveshaf t i s t o b e removed , th e senso r shoul d firs [...]

  • Página 102

    Lotu s Servic e Note s Sectio n D E i ) Us e th e uppermos t sprin g abutmen t groov e o n bot h fron t an d rea r dampe r bodies . ii ) Replac e eac h rea r dampe r to p mountin g bracke t wit h ne w bracke t A111D0076F , togethe r wit h loa d spreadin g plat e A111D0125F . Discar d th e plai n washer s previousl y use d o n th e fixin g bolts . N[...]

  • Página 103

    Lotu s Servic e Note s Sectio n TDM ENGIN E SECTIO N E E - M11 1 ELIS E Genera l Descriptio n Maintenanc e Operation s Engin e Removal/Replacemen t Specia l Tool s Sub-Sectio n Paa e EE. 1 1 EE. 2 1 EE. 3 5 EE. 4 6 Page 1[...]

  • Página 104

    Lotu s Servic e Note s Sectio n TDM EE. 1 - GENERA L DESCRIPTIO N Th e 1. 8 litre , 1 6 valv e fou r cylinde r engin e use d i n th e Lotu s Elis e i s supplie d b y Rove r Group , an d i s designate d 'K16' . A ful l descriptio n an d overhau l procedur e fo r thi s uni t i s containe d i n th e Rove r Overhau l Manua l RC L 0057ENG , a [...]

  • Página 105

    Lotu s Servic e Note s Sectio n TDM Oi l Filte r Th e oi l filte r i s horizontall y mounte d a t th e fron t o f th e engine , an d i s accessibl e fro m beneat h (remov e th e engin e ba y undershield / diffuse r i f applicable) . Th e filte r shoul d b e re - newed , a t interval s specifie d i n th e Mainte - nanc e Schedule , b y turnin g i n [...]

  • Página 106

    Lotu s Servic e Note s Sectio n TDM T o replac e th e filte r element , leav e th e hos e attached , an d releas e th e fou r over-centr e clip s securin g th e to p cove r o f th e ai r filte r housing . Rais e th e cove r an d ensur e tha t th e filte r elemen t remain s i n th e lowe r housin g befor e swingin g th e cove r aside . Lif t ou t th[...]

  • Página 107

    Lotu s Servic e Note s Sectio n TDM EE. 3 - ENGIN E REMOVAL/REPLACEMEN T Th e engin e ma y b e remove d fro m above , wit h o r withou t th e rea r clamshel l i n position . I t i s recom - mende d t o remov e th e clamshel l fo r improve d access , an d t o reduc e th e possibilit y o f pain t damage . I f th e clamshel l i s lef t 'i n situ&[...]

  • Página 108

    Lotu s Servic e Note s Sectio n TDM 11 . Releas e th e clutc h slav e cylinde r fro m th e mountin g bracket , an d suppor t aside . 12 . Releas e th e coolan t outle t hos e fro m th e pip e a t th e fron t o f th e engin e bay , an d releas e th e pip e 'P ' cli p fro m it s bracke t a t th e fron t o f th e engine . Releas e th e coola[...]

  • Página 109

    K ' SERIE S ENGIN E OVERHAU L MANUA L Thi s overhau l manua l i s applicabl e t o 'K ' Serie s engine s fitte d wit h eithe r VV C o r no n VV C cylinde r head s an d 'damp ' cylinde r liners . Thi s engin e i s fitte d t o th e followin g models : MGF , Rove r 11 4 an d 214/41 4 Ne w Rove r 214 , 216 , 21 8 an d BR M Ne w [...]

  • Página 110

    INTRODUCTIO N CONTENT S Pag e INTRODUCTIO N INTRODUCTIO N 1 REPAIR S AN D REPLACEMENT S 1 SPECIFICATIO N 2 ENGIN E NUMBE R LOCATIO N 2 ENGIN E SERIA L NUMBE R PREFIXE S 2 COMMENCIN G ENGIN E NUMBER S 2 K1 6 No n VV C engine s fitte d wit h automati c timin g bel t tensione r 2 K1 6 No n VV C engine s fitte d wit h modifie d camshaft s an d cylinde [...]

  • Página 111

    INTRODUCTIO N INTRODUCTIO N Ho w t o us e thi s manua l T o assis t i n th e us e o f thi s manua l th e sectio n titl e i s give n a t th e to p an d th e relevan t sub-sectio n i s give n a t th e botto m eac h page . T o hel p reader s fin d th e informatio n the y need , th e firs t pag e o f eac h sectio n i s marke d wit h a blac k tab . I n [...]

  • Página 112

    INTRODUCTIO N SPECIFICATIO N Rove r ar e constantl y seekin g t o improv e th e specification , desig n an d productio n o f thei r vehicle s an d alteration s tak e plac e accordingly . Whil e ever y effor t ha s bee n mad e t o ensur e th e accurac y o f thi s Manual , i t shoul d no t b e regarde d a s a n infallibl e guid e t o curren t specifi[...]

  • Página 113

    K1 6 No n VV C engine s fitte d wit h modifie d camshaft s an d cylinde r head s 14K4FK7 6 872191 , 14K4FK7 7 87238 2 14K4FL3 0 114520 , 14K4FL3 0 87204 1 14K4FL3110407 3 16K4FK7 9 872751 , 16K4FK8 0 87228 5 16K4FL3 2 114135 , 16K4FL3 3 11283 7 16K4FL3 4 110965 , 16K4FL3 5 11054 1 18K4FJ3 1 112397 , 18K4FJ3 2 11128 1 18K4FJ7 8 115630 , 18K4FJ7 9 11[...]

  • Página 114

    ENGIN E Thi s pag e i s intentionall y lef t blan k 114 DESCRIPTIO N AN D OPERATIO N[...]

  • Página 115

    IN E DESCRIPTIO N AN D OPERATIO N[...]

  • Página 116

    ENGIN E Thi s pag e i s intentionall y lef t blan k 116 DESCRIPTIO N AN D OPERATIO N[...]

  • Página 117

    IGIN E DESCRIPTIO N AN D OPERATIO N[...]

  • Página 118

    ENGIN E CYLINDE R BLOC K COMPONENT S 1 . Oi l pum p assembl y 39 . Mai n bearin g shell s 2 . Gaske t - oi l pum p Plai n i n bloc k Nos. 1 an d 5 3 . Scre w - M 6 x 3 0 - oi l pum p Groove d i n bloc k Nos . 2 , 3 an d 4 . Scre w M 6 x 2 0 - oi l pum p Plai n i n bearin g ladde r 5 . Crankshaf t fron t oi l sea l 40 . Thrus t washer s 6 . Dipstic [...]

  • Página 119

    GIN E DESCRIPTIO N AN D OPERATIO N[...]

  • Página 120

    ENGIN E CYLINDE R HEA D COMPONENT S - K 8 ENGINE S 1 . Engin e oi l fille r ca p 2 . Fille r ca p sea l 3 . h t cli p mountin g bracke t 4 . Cli p - 2 h t lead s 5 . Bolt , bracke t 6 . Camshaf t cove r 7 . Gaske t 8 . Bol t - camshaf t cove r 9 . Cylinde r hea d bol t 10 . h t cli p mountin g bracke t 11 . Cli p - 4 h t lead s 12 . Bolt , bracke t[...]

  • Página 121

    ENGIN E 6 DESCRIPTIO N AN D OPERATIO N[...]

  • Página 122

    ENGIN E CYLINDE R HEA D COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H DISTRIBUTO R 1 . Spar k plu g cove r 2 . Scre w M 4 - cove r 3 . Scre w retainin g washe r 4 . Engin e oi l fille r ca p 5 . Fille r ca p sea l 6 . Sparkplu g 7 . Clip-h t lead s 8 . Bol t M 6 - camshaf t cove r 9 . Camshaf t cove r 10 . Camshaf t cove r gaske t 11 . Camsha[...]

  • Página 123

    O N AN D OPERATIO N[...]

  • Página 124

    ENGIN E CYLINDE R HEA D COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H PLU G TO P COI L IGNITIO N SYSTE M 1 . Spar k plu g cove r 2 . Scre w - spar k plu g cove r 3 . h t lea d an d plu g tub e 4 . Oi l fille r ca p 5 . Sea l - oi l fille r ca p 6 . Screw s - coil s t o camshaf t cove r 7 . Coi l 8 . Sparkplu g 9 . Bol t - camshaf t cove r 10 [...]

  • Página 125

    ENGIN E J—5 1 M1 2 725 7 DESCRIPTIO N AN D OPERATIO N 10[...]

  • Página 126

    ENGIN E 1-S3 ] CYLINDE R HEA D COMPONENT S • K1 6 VV C ENGINE S 1 . Bolt s - hydrauli c contro l uni t 2 . Hydrauli c contro l uni t bod y an d spoo l valv e 3 . Solenoid s 4 . 'O * ring s 5 . Spoo l valv e nu t 6 . Oi l temperatur e transmitte r 7 . Pisto n screw , pisto n an d sea l assembl y 8 . Rac k 9 . Sea l plat e 10 . Labyrint h seal[...]

  • Página 127

    ENGIN E TIMIN G BEL T COMPONENT S - K 8 ENGINE S M.12493 4 1 . Uppe r fron t cove r - timin g bel t 2 . Sea l - uppe r cove r 3 . Scre w M 6 x 1 6 - uppe r cove r 4 . Bol t M 6 x 4 0 - uppe r cove r 5 . Bol t M 6 x 2 0 - uppe r cove r 6 . Flang e shoulde r scre w - uppe r cove r 7 . Lowe r cove r - timing-bel t 8 . Sea l - lowe r cove r t o mountin[...]

  • Página 128

    ENGIN E TIMIN G BEL T COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H MANUA L TIMIN G BEL T TENSIONE R 2 4 M12493 3 1 . Uppe r fron t cove r - timin g bel t 2 . Scre w M 6 - uppe r cove r 3 . Sea l - uppe r cove r 4 . Bol t M 6 x 9 0 - uppe r an d lowe r cove r 5 . Lowe r cove r - timin g bel t 6 . Sea l - lowe r cove r 7 . Scre w M 6 - lowe r [...]

  • Página 129

    ENGIN E TIMIN G BEL T COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H AUTOMATI C TIMIN G BEL T TENSIONE R 1 . Uppe r fron t cove r - timin g bel t 2 . Scre w M 6 - uppe r cove r 3 . Sea l - uppe r cove r 4 . Bol t M 6 x 9 0 - uppe r an d lowe r cover s 5 . Lowe r cove r - timin g bel t 6 . Sea l - lowe r cove r 7 . Scre w M 6 - lowe r cove r 8 [...]

  • Página 130

    ENGIN E FRON T TIMIN G BEL T COMPONENT S - K1 6 VV C ENGINE S 12M3527 A 1 . Scre w - uppe r fron t cove r 2 . Uppe r fron t cove r - timin g bel t 3 . Camshaf t gea r bol t 4 . Washe r 5 . Tensione r sprin g * 6 . Pilla r bolt * 7 . Alle n scre w - tensione r pulle y 8 . Tensione r pulle y an d backplat e 9 . Flange d hea d scre w - tensione r back[...]

  • Página 131

    ENGIN E REA R TIMIN G BEL T COMPONENT S - K1 6 VV C ENGINE S 12M352 8 1 . Scre w - rea r timin g bel t cove r 2 . Rea r timin g bel t cove r 3 . Rea r timin g bel t 4 . Bol t - M 8 - rea r timin g gea r 5 . Washe r - rea r timin g gea r bol t 6 . Exhaus t camshaf t rea r timin g gea r 7 . Rea r timin g bel t backplat e 8 . Bol t - rea r timin g bel[...]

  • Página 132

    ENGIN E OPERATIO N Th e K Serie s engin e i s buil t u p fro m aluminiu m casting s bolte d together . Thes e consis t o f thre e majo r castings ; th e cylinde r head , cylinde r bloc k an d a bearin g ladde r whic h i s lin e bore d t o provid e th e mai n bearin g bores . Attache d t o thes e ar e thre e mino r castings ; abov e th e cylinde r h[...]

  • Página 133

    ENGIN E Whils t th e exhaus t camshaf t i s simila r t o camshaft s fitte d t o no n VV C K1 6 engines , ther e ar e fou r inle t camshafts , assemble d i n pairs , eac h individua l camshaf t operatin g th e inle t valve s o n on e cylinder . Th e fron t pai r o f camshaft s ar e driven , vi a th e fron t VV C mechanism , b y th e camshaf t timin [...]

  • Página 134

    DESCRIPTIO N AN D OPERATIO N 111[...]

  • Página 135

    ENGIN E K1 6 engin e lubricatio n syste m 12M1758 A No n VV C camshaft s illustrate d DESCRIPTIO N AN D OPERATIO N 20[...]

  • Página 136

    ENGIN E Lubricatio n Th e lubricatio n syste m i s o f th e full-flo w filtration , force d fe d type . Th e oi l sum p i s o f eithe r presse d stee l o r allo y manufacture . Presse d stee l sump s ar e seale d t o th e bearin g ladde r usin g a positivel y locate d gaske t incorporatin g compressio n limiters . Allo y sump s ar e seale d t o th [...]

  • Página 137

    ENGIN E CONTENT S Pag e DESCRIPTIO N AN D OPERATIO N CYLINDE R BLOC K COMPONENT S 3 CYLINDE R HEA D COMPONENT S - K 8 ENGINE S 5 CYLINDE R HEA D COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H DISTRIBUTO R 7 CYLINDE R HEA D COMPONENT S - K1 6 NO N VV C ENGINE S FITTE D WIT H PLU G TO P COI L IGNITIO N SYSTE M 9 CYLINDE R HEA D COMPONENT S - K1 [...]

  • Página 138

    ENGIN E CAMSHAF T TIMIN G BEL T - K B ENGINE S Remov e CAUTION : D o no t us e camshaf t gear , gea r /j retainin g bol t o r timin g bel t t o rotat e crankshaft . 328 3 M12496 0 5 . Chec k tha t timim g mar k o n crankshaf t pulle y i s aligne d wit h mar k o n timin g bel t lowe r cover . 1 . Slacke n botto m bol t securin g timin g bel t uppe[...]

  • Página 139

    ENGIN E 8RM3458 A 8 . Remov e crankshaf t pulle y bol t an d washer . 9 . Remov e crankshaf t pulley . 10 . Remov e 3 bolt s securin g timin g bel t lowe r cover . 11 . Remov e timin g bel t lowe r cove r togethe r wit h seals . 12 . Remov e 3 bolts , mountin g bracke t t o engine . 13 . Remov e mountin g bracket . M12494 4 14 . Slacke n tensione r[...]

  • Página 140

    ENGIN E 9 . Ensur e insert s ar e fitte d i n timin g bel t lowe r cover . 10 . Fi t timin g bel t lowe r cover , ensurin g correc t positio n o f seals , tighte n screw s t o 1 0 Nm . 12M375 7 15 . Wit h tensione r pulle y agains t timin g bel t an d backplat e hel d i n position , tighte n backplat e scre w t o 1 0 Nm . 16 . Rotat e crankshaf t c[...]

  • Página 141

    ENGIN E CAMSHAF T TIMIN G BEL T - K1 6 ENGINE S Camshaf t timin g bel t - manua l tensione r • remov e - CAUTION : Timin g belt s fitte d t o engine s /j wit h manua l timin g bel t tensioner s ar e no t interchangeabl e wit h belt s fitte d t o engine s wit h automati c tensioners . M12497 4 /r n A NOTE : Tw o type s o f timin g bel t tensione[...]

  • Página 142

    ENGIN E Flywheel not fitted with a reluctor ring iacis7 i 6 . Fi t flywhee l lockin g too l 18 G 1571 . 7 . Secur e wit h 2 bolts . Flywheel fitted with a reluctor ring A NOTE : VV C camshaf t timin g gea r mark s ar e show n i n th e inse t o n th e illustration . 3 . Rotat e crankshaf t clockwis e t o alig n camshaf t gea r timin g mark s - 90 °[...]

  • Página 143

    ENGIN E All engines 8RM3461 A 9 . Remov e crankshaf t pulle y bol t an d washer , remov e crankshaf t pulley . 10 . Remov e 3 bolt s securin g timin g bel t lowe r . cover . 11 . Remov e timin g bel t lowe r cove r togethe r wit h seals . M12492 5 A NOTE : No n VV C camshaf t timin g gear s an d tensione r sprin g illustrated . 12 . Slacke n tensio[...]

  • Página 144

    ENGIN E Camshaf t timin g bel t - manua l tensione r - refi t A CAUTION : VV C engines: - Whe n a / j replacemen t timin g bel t i s t o b e fitted , i t wil l b e necessar y t o fi t th e tensione r sprin g an d pilla r bol t supplie d wit h th e replacemen t bel t t o adjus t bel t tension . 1 . Clea n timin g gears , coolan t pum p driv e gea [...]

  • Página 145

    ENGIN E Flywheel fitted with a reluctor ring 18G167 4 M12493 7 5 . Fi t flywhee l lockin g too l 18 G 1674 , tighte n bolt . A CAUTION : Ensur e toot h o n too l 18 G 167 4 engage s wit h teet h o n flywhee l no t th e relucto r ring . 6 . VVC engines: Fi t tensione r sprin g an d pilla r bol t supplie d wit h replacemen t timin g belt , connec t s[...]

  • Página 146

    ENGIN E 13 . Fi t crankshaf t pulle y t o crankshaf t timin g gea r ensurin g tha t inden t o n pulle y locate s ove r lu g o n gear . 14 . Secur e wit h crankshaf t pulle y bol t an d washer , tighte n t o 20 5 Nm . 15 . Remov e camshaf t an d flywhee l lockin g tools . A NOTE : No n VV C camshaf t timin g gear s an d tensione r sprin g illustrate[...]

  • Página 147

    ENGIN E VVC engines 21 . Disconnec t tensione r sprin g fro m pilla r bolt , releas e sprin g fro m tensioner ; remov e an d discar d spring . 22 . Remov e an d discar d pilla r bolt . All engines 23 . Ensur e insert s ar e fitte d i n timin g bel t fron t uppe r cover . 24 . Fi t timin g bel t uppe r fron t cover , ensurin g correc t positio n o f[...]

  • Página 148

    ENGIN E tOM^ ^ M12495 2 4 . Rotat e crankshaf t clockwis e t o alig n camshaf t gea r timin g mark s - 90 " BTDC . ~ CAUTION : D o no t us e camshaf t gears , / j gea r retainin g bolt s o r timin g bel t t o rotat e crankshaft . 5 . Fi t camshaf t gea r lockin g too l 18 G 1570 . M12494 9 6 . Chec k tha t timin g mar k o n crankshaf t pulle[...]

  • Página 149

    ENGIN E M12494 5 8 . Remov e crankshaf t pulle y bol t an d washer . 9 . Remov e crankshaf t pulley . 10 . Remov e 3 bolt s securin g timin g bel t lowe r cover . 11 . Remov e timin g bel t lowe r cove r togethe r wit h seals . M12495 5 12 . Remov e an d discar d timin g bel t tensione r bolt . 13 . Disengag e inde x wir e fro m it s fitte d positi[...]

  • Página 150

    4 . Fi t flywhee l lockin g too l 18 G 1674 . 5 . Fi t timin g bel t tensione r ensurin g tha t inde x wir e i s positione d ove r pilla r bol t an d tha t tensione r leve r i s a t 9 o'cloc k position . 6 . Fi t a ne w tensione r securin g bol t an d tighte n bol t unti l i t i s jus t possibl e t o mov e tensione r lever . 7 . Usin g th e fi[...]

  • Página 151

    ENGIN E M12495 7 14 . Usin g a 6 m m Alle n key , rotat e tensione r anti-clockwis e an d alig n th e centr e o f th e inden t o n th e tensione r pointe r t o th e inde x wire . CAUTION : Ensur e tha t pointe r approache s /j inde x wir e fro m above . Shoul d pointe r g o pas t inde x wire , releas e tensio n completel y an d repea t tensionin [...]

  • Página 152

    ENGIN E 22 . Ensur e insert s ar e fitte d i n timin g bel t uppe r fron t cover . 23 . Fi t timin g bel t uppe r fron t cove r ensurin g correc t positio n o f seal , fi t screws , tighte n screw s an d botto m bol t t o 5 Nm . OI L PUM P Remov e 1 . Remov e an d discar d camshaf t timin g belt . 2 . Remov e crankshaf t timin g gear . 3 . Notin g [...]

  • Página 153

    ENGIN E Inspectio n 12M176 7 12M176 8 1 . Remov e 2 screw s an d cove r plate . 2 . Remov e an d discar d cove r plat e seal . « CAUTION : Tw o type s o f oi l pum p hav e / j bee n fitted . Th e earl y typ e oi l pumps , fitte d u p t o Engin e No . 820000 , ca n b e identifie d b y havin g eithe r a plai n 6 m m diamete r oi l fee d hol e o r [...]

  • Página 154

    ENGIN E )i i pressur e relie f valv e 1 . Unscre w plug , discar d sealin g washer . 2 . Remov e sprin g an d relie f valv e sleev e assembly . 3 . Chec k tha t valv e sleev e slide s freel y i n bor e an d tha t bor e an d sleev e ar e fre e fro m scorin g an d corrosion . A NOTE : Ligh t corrosio n ma y b e remove d usin g grad e 60 0 emer y clot[...]

  • Página 155

    ENGIN E Oi l pum p - refi t 1 . Clea n oi l pump . 2 . Usin g gaske t remova l spra y an d a plasti c scraper , remov e al l trace s o f gaske t fro m oi l pump . 3 . Clea n oi l sea l runnin g surfac e o n crankshaft . 4 . Fi t a new , dry , oi l pum p gasket . 5 . Tur n oi l pum p roto r t o alig n driv e wit h crankshaft . 6 . Fi t oi l sea l pr[...]

  • Página 156

    ENGIN E COOLAN T PUM P Remov e 1 . Remov e an d discar d camshaf t timin g belt . 2 . Remov e thermosta t an d housing . 3 . Rear cover fitted: Remov e scre w securin g timin g bel t rea r cove r t o coolan t pump . 4 . Notin g thei r fitte d position , remov e bolt s an d pilla r bol t securin g coolan t pump . ~ NOTE : 2 pilla r bolt s ar e fitte[...]

  • Página 157

    ENGIN E THERMOSTA T Remov e 12M055 8 1 . Remov e 2 bolt s securin g coolan t rai l t o cylinde r block , releas e rai l fro m thermosta t cover . 2 . Remov e bol t securin g thermosta t housin g an d dipstic k tub e t o cylinde r block . 3 . Withdra w thermosta t housin g fro m coolan t pump . Inspectio n 1 . Tes t thermosta t usin g thermosta t te[...]

  • Página 158

    ENGIN E FLYWHEE L AN D STARTE R RIN G GEA R Flywhee l - remov e 1B G 157 1 18G167 4 Is r z / I y A 8H M 347 7 NOTE : Flywhee l withou t relucto r rin g illustrated . 2 . Remov e an d discar d 6 bolt s securin g flywheel . 3 . Usin g assistance , remov e flywhee l fro m crankshaft . M12493 7 A NOTE : Dowe l located . 1 . Fi t flywhee l lockin g tool[...]

  • Página 159

    ENGIN E Starte r rin g gea r - remov e 12M1936 A 1 . Remov e flywheel . 2 . Dril l a 3 m m diamete r hol e a t roo t o f 2 teeth . 3 . Appl y a col d chise l t o roo t o f teeth , brea k ring gea r an d remov e fro m flywheel . WARNING : Suitabl e ey e protectio n mus t b e worn . Starte r rin g gea r - refi t 1 . Hea t ring gea r evenl y t o 350°[...]

  • Página 160

    CYLINDE R HEA D Cylinde r hea d - K 8 engine s - remov e ~ CAUTION : I f crankshaf t i s t o b e remove d /j durin g overhaul , i t wil l b e necessar y t o chec k an d recor d crankshaf t end-floa t prio r t o removin g cylinde r head . 12M054 9 1 . Remov e an d discar d camshaf t timin g belt . ~ CAUTION : D o no t rotat e crankshaf t whils t j[...]

  • Página 161

    ENGIN E 12M0548 A 11 . Us e too l 12-18 2 t o hol d camshaf t gea r agains t rotation . 12 . Remov e bol t an d plai n washe r securin g camshaf t gear . 13 . Remov e camshaf t gear . 14 . Remov e screw s securin g uppe r par t o f timin g bel t rea r cove r t o cylinde r hea d an d scre w securin g rea r o f cove r t o coolan t pump , remov e cove[...]

  • Página 162

    ENGIN E Cylinde r hea d - K1 6 No n VV C engine s fitte d wit h distributo r - remov e A CAUTION : I f crankshaf t i s t o b e remove d /} durin g overhau l i t wil l b e necessar y t o chec k an d recor d crankshaf t end-floa t prio r t o removin g cylinde r head . 18G157 0 Ml2493 0 1S G 173 6 12M177 0 19 . Assembl e cylinde r line r retaine r c[...]

  • Página 163

    ENGIN E M12493 1 3 . Releas e 2 screw s an d remov e spar k plu g cover . 4 . Disconnec t 4 plu g tube s fro m spar k plugs . Remov e an y debri s fro m spar k plu g recesses , remov e an d discar d 4 spar k plugs . 5 . Lif t cli p plat e an d gromme t an d positio n plu g lead s aside . 6 . Remov e 2 bolt s an d ai r cleane r suppor t bracket . 7 [...]

  • Página 164

    ENGIN E JC L ^DQ@DA®DA®I ! Q 8R M 074 0 14 . Usin g sequenc e shown , progressivel y slacke n cylinde r hea d bolts : Early engines:- bolt s 1 t o 8 , remov e bolt s 1 t o 8 an d stor e i n fitte d order . Later engines fitted with modified camshafts:- bolt s 1 t o 6 , remov e bolt s 1 t o 6 an d stor e i n fitte d order . A NOTE : I t wil l b e [...]

  • Página 165

    ENGIN E 12M177 0 23 . Assembl e cylinde r line r retaine r clamp s 18 G 173 6 t o cylinde r hea d bolts . Positio n retaine r clamp s o n cylinde r liner s ensurin g damp s d o no t protrud e ove r line r bores . Scre w cylinde r hea d bolt s int o oi l rai l an d tighte n sufficientl y t o retai n clamps . CAUTION : Ensur e tha t bolt s use d ar e[...]

  • Página 166

    ENGIN E If fitted Ml2495 0 ^ a Cylinde r hea d - K1 6 no n VV C engine s fitte d wit h plu g to p coi l ignitio n syste m - remov e NOTE : Commencin g engin e number s fo r thes e engine s ar e liste d i n Informatio n A ~ CAUTION : I f crankshaf t i s t o b e remove d /} durin g overhau l i t wil l b e necessar y t o chec k an d recor d cranksha[...]

  • Página 167

    ENGIN E 12 . Remov e bol t securin g camshaf t senso r t o camshaf t cover , withdra w sensor . 13 . Remov e an d discar d 'O ' ring. 14 . Releas e harnes s fro m clip . 15 . Positio n harnes s aside . camshaf t carrier , remov e bracket . All cylinder heads 17 . Remov e an y debri s fro m spar k plu g recesses , remov e 4 spar k plugs . [...]

  • Página 168

    ENGIN E raj 18G157 0 12-18 2 Ml2496 9 A NOTE : Timin g bel t rea r cove r fitte d t o engin e wit h 5 bol t fron t engin e mountin g illustrated . M1 2 4964 A 28 . Remov e scre w securin g rea r o f timin g bel t rea r cove r t o coolan t pump . A NOTE : Thi s i s th e longes t o f th e rea r cove r securin g screws . 22 . Remov e camshaf t lockin [...]

  • Página 169

    ENGIN E 11 0 173 6 12M177 0 33 . Assembl e cylinde r line r retaine r clamp s 18 G 173 6 t o cylinde r hea d bolts . Positio n retaine r clamp s o n cylinde r liner s ensurin g clamp s d o no t protrud e ove r line r bores . Scre w cylinde r hea d bolt s int o oi l rai l an d tighte n sufficientl y t o retai n clamps . CAUTION : Ensur e tha t bolt [...]

  • Página 170

    ENGIN E > . Remov e screw s securin g timin g bel t uppe r rea r cove r t o cylinde r hea d an d rea r o f cove r t o coolan t pump , remov e cover . rt NOTE : Thi s i s th e longes t o f th e rea r cove r securin g screw s 6 7 i i- T M12725 6 A NOTE : Camshaf t cove r fitte d t o earl y engine s illustrated . 6 . Remov e 2 screw s securin g s[...]

  • Página 171

    ENGIN E All engines M1 2 633 1 ~ NOTE : Camshaf t cove r fitte d t o earl y / engine s illustrated . 15 . Progressivel y slacken , the n remov e 1 5 bolt s securin g camshaf t cover . 16 . Remov e camshaf t cover , remov e an d discar d gasket . 17 . Chec k an d recor d crankshaf t end-float . 20 . Usin g assistance , remov e cylinde r hea d asse[...]

  • Página 172

    ENGIN E Camshaft s - K1 6 VV C engine s - chec k end-floa t Inlet camshafts 12M349 3 Camshaft s - K 8 an d al l K1 6 No n VV C engine s - chec k end-floa t 1 . Chec k end-floa t o f eac h camshaf t usin g a DTI . Camshaf t end-floa t = 0.0 6 t o 0.1 9 m m Servic e limi t = 0. 3 m m 2 . Rene w component s a s necessar y t o achiev e correc t end-flo[...]

  • Página 173

    ENGIN E Exhaust camshaft 6 . Chec k camshaf t end-floa t usin g a DTI . Exhaus t camshaf t end-floa t = 0.0 6 t o 0.1 9 m m Sen/ic e limi t = 0. 3 m m 7 . Rene w component s a s necessar y t o achiev e correc t end-float . Camshaf t carrie r an d camshaft s - K 8 an d al l K1 6 No n W C engine s - remov e K8 1 . Usin g sequenc e shown , progressive[...]

  • Página 174

    ENGIN E M12493 6 K16 M12497 3 ~ CAUTION . Camshaft s fitte d t o late r /! engine s incorporat e a relucto r ring , thes e camshaft s ar e no t interchangeabl e wit h thos e fitte d t o earl y engines . Commencin g engin e number s fo r th e modifie d camshaft s ar e liste d i n Information . A NOTE : Camshaft s incorporatin g a relucto r rin g i[...]

  • Página 175

    ENGIN E Camshaf t carrie r an d camshaft s - K1 6 W C engine s - remov e 12M348 1 1 . Remov e 4 bolt s securin g camshaf t rea r bel t cover , remov e cover . 2 SS^ 12M3482 A 2 . Usin g too l 12-182 , rotat e inle t camshaf t rea r timin g gea r unti l timin g mark s o n bot h rea r gear s ar e facin g outwards . . NOTE : Wit h timin g mark s i n t[...]

  • Página 176

    ENGIN E 12M3486 A 10 . Remov e oi l temperatur e transmitter , fro m hydrauli c contro l unit , remov e an d discar d sealin g washer . 11 . Remov e 3 bolt s securin g hydrauli c contro l uni t t o camshaf t carrier . 12 . Withdra w hydrauli c contro l unit , remov e sea l plate . 13 . Remov e an d discar d 2 labyrint h seal s an d rac k sea l fro [...]

  • Página 177

    ENGIN E 12M348 9 ~ CAUTION : Durin g th e followin g / j operations , i t i s essentia l t o ensur e tha t fron t an d rea r inle t camshaft s ar e retaine d i n thei r respectiv e VV C assemblies . I f camshaft s ar e remove d fro m thei r VV C assemblies , the n complet e assembl y mus t b e replaced ; i t i s no t permissibl e t o refi t camsh[...]

  • Página 178

    ENGIN E 18G177 0 18G1770/ 1 12M352 1 32 . Remov e exhaus t camshaf t fro m cylinde r head . 3 0 12M349 0 26 . Fi t timin g plate s 18 G 1770/ 1 t o fron t an d 18 G 1770/ 2 t o rea r VV C assemblies . 27 . Assembl e clamp s 18 G 177 0 t o fron t an d rea r inle t camshaft s an d VV C assemblies , fi t camshaf t gea r bolt s an d washer s t o retai [...]

  • Página 179

    ENGIN E Tappet s - inspectio n 1 . Chec k tappet s fo r sign s o f wear , scorin g an d overheating . 2 . Measur e outsid e diamete r o f tappet , measuremen t mus t b e take n half-wa y alon g tappe t body . Tappe t outsid e di a = 32.95 9 t o 32.97 5 mm . 3 . Ensur e oi l hol e i n eac h tappe t i s clear . A NOTE . Retai n tappet s i n thei r fi[...]

  • Página 180

    ENGIN E 12M054 7 6 . Measur e wides t portio n o t Plastigag e o n eac h journal : Camshat t bearin g clearanc e = 0.06 0 t o 0.09 4 m m Servic e limi t = 0.1 5 m m I f clearanc e i s excessive , fi t ne w camshaft(s ) an d repea t check . I f clearance s ar e stil l excessive , replac e cylinde r hea d an d camshaf t carrie r assembly . CAUTION : [...]

  • Página 181

    ENGIN E Timin g gear s - No n VV C engine s 1 . Clea n timin g gears , chec k gea r teet h fo r damag e an d driv e pi n slo t fo r wear , replac e gear s a s necessary . ~ CAUTION : I f gear s hav e bee n subjecte d t o / j prolonge d exposur e t o oi l contamination , the y mus t b e soake d i n a solven t bat h an d the n thoroughl y washe d i[...]

  • Página 182

    ENGIN E Checkin g camshaf t bearin g clearanc e - VV C engine s 1 . Positio n exhaus t camshaf t i n cylinde r hea d an d plac e a stri p o f Plastigag e acros s eac h camshaf t journal . 18G177 0 « CAUTION : Durin g th e followin g operation s /j i t i s essentia l t o ensur e tha t fron t an d rea r inle t camshaft s ar e retaine d i n thei r [...]

  • Página 183

    ENGIN E 18G177 0 18G1770/ 2 18G177 0 1 6 12M3518 A 1 7 r ) u W n p a § is s 12M366 6 17 . Measur e wides t portio n o f Plastigag e o n eac h inle t camshaf t journa l o n camshaf t carrier : Inle t camshaf t bearin g journa l clearances : 2 5 m m diamete r journal s = 0.02 5 t o 0.06 0 m m Servic e limi t = 0. 1 m m 4 0 m m diamete r journal s = [...]

  • Página 184

    ENGIN E ~ CAUTION : I f replacemen t exhaus t /! camshaf t i s t o b e fitted , ensur e i t i s correc t fo r engin e bein g worke d on . A NOTE : Inle t camshaft s ar e onl y supplie d wit h VV C mechanism s a s a n assembly . 20 . Remov e exhaus t camshaf t fro m cylinde r head . 21 . Remov e al l trace s o f Plastigag e usin g a n oil y rag . [...]

  • Página 185

    ENGIN E /alve s an d spring s - remov e 1 . Suppor t cylinde r hea d clea r o f valves ; us e hollo w drif t an d ta p eac h sprin g ca p t o fre e collets . 2 . Positio n cylinde r hea d o n it s exhaus t manifol d face . A NOTE : K1 6 engine . Remov e inle t valve s wit h cylinde r hea d i n thi s position . A NOTE : K1 6 No n VV C cylinde r hea [...]

  • Página 186

    ENGIN E •K G 157 7 Cylinde r hea d - cleanin g 1 . Clea n sealin g surface s o n cylinde r hea d an d camshaf t canier . Us e foa m actio n gaske t remove r an d a plasti c scrape r - D O NO T US E A META L SCRAPE R O N SEALIN G SURFACES . Clea n inle t an d exhaus t manifol d join t faces . 2 . De-carbonis e combustio n area s o f cylinde r hea [...]

  • Página 187

    ENGIN E Cylinde r hea d - inspectio n Valv e spring s - inspectio n 1 . Chec k cylinde r hea d fo r damage , pa y particula r attentio n t o gaske t fac e o f cylinde r head . 1 . Chec k conditio n o f valv e springs : A NOTE : Valv e spring s ar e eithe r colou r code d o r plain : 8H M 362 8 2 . Chec k cylinde r hea d fac e fo r warping , acros s[...]

  • Página 188

    A NOTE : Tw o type s o f exhaus t valv e ma y b e fitted , standar d valves , A i n illustratio n o r carbon brea k valves , B i n illustration . Carbo n brea k valve s ma y b e identifie d b y th e machine d profil e C o n th e valv e stem . T o preven t exhaus t valve s fro m sticking , standar d valve s shoul d b e replace d wit h carbo n brea k[...]

  • Página 189

    ENGIN E KB Valv e guide s - rene w Valv e ste m diamete r A : Inle t = 6.96 0 t o 6.97 5 m m Exhaus t = 6.95 2 t o 6.96 7 m m Valv e guides : Insid e diamete r B: = 7.00 0 t o 7.02 5 m m Valv e ste m t o guid e clearanc e C : Inle t = 0.02 5 t o 0.06 5 m m Sen/ic e limi t = 0.0 7 m m Exhaus t = 0.03 3 t o 0.07 3 m m Servic e limi t = 0.1 1 m m K16 [...]

  • Página 190

    ENGIN E 18 G 1576- 1 18 G 157 6 3 K 8 18G1576- 4 1 K1 6 18G1576- 2 8R M 007 6 A Valv e sea t insert s - rene w _ CAUTION : Tripl e angl e valv e sea t insert s /! hav e bee n introduce d o n late r K1 6 engines ; thes e insert s ar e no t interchangeabl e wit h thos e fitte d t o earl y engines . Commencin g engin e number s fo r engine s fitte d[...]

  • Página 191

    ENGIN E K8 - See illustration 8RM 1102A Inle t A: = 29.4 2 t o 29.5 7 m m B: = 31.6 1 t o 31.9 1 m m C: = 35.59 4 t o 35.61 4 m m D: = 35 ° E: = 35.50 0 t o 35.52 5 m m F: = 5.4 5 t o 5.5 0 m m G: = 5.9 5 t o 6.0 5 m m H: = 2. 0 m m radiu s J: = 0.7 5 t o 1.2 5 m m K: = 45 ° Exhaus t A: = 26.9 2 t o 27.0 7 m m B: = 2 8 7 3 t o 29.0 3 m m C: = 33.[...]

  • Página 192

    ENGIN E K16 - VVC engines fitted with triple angle valve seats • See illustration M12 5536 K16 - Non WC engines fitted with triple angle valve seats - See illustration M12 5536 Inle t A: = 15 ° B: = 45 ° C: = 60 ° 0: = 0. 4 m m radiu s E: = 32.56 0 t o 32.57 3 m m F: = 1. 0 t o 1. 4 m m G: = 30. 2 m m H: = 32.47 5 t o 32.50 0 m m J: = 5.9 5 t [...]

  • Página 193

    ENGIN E Valv e seat s - refacin g ~ CAUTION : Rene w wor n valv e guide s / ! befor e refacin g valve s an d seats . 1 . Chec k conditio n o f valv e seat s an d existin g valve s tha t ar e t o b e re-used . 3 . La p eac h valv e t o sea t usin g fin e grindin g paste . 4 . Appl y Prussia n Blu e t o valv e seat , inser t valv e an d pres s i t [...]

  • Página 194

    ENGIN E K1 6 VV C housin g gasket s - remov e 1 . Secur e VV C housin g an d camshaf t i n a soft-jawe d vic e wit h camshaf t positione d upwards . ~ CAUTION : Onl y tighte n vic e sufficientl y t o ! retai n housing , damag e t o mechanis m wil l resul t i f vic e i s overtightened . 2 . Takin g car e no t t o allo w camshaf t t o becom e separ[...]

  • Página 195

    ENGIN E Hydrauli c contro l uni t - K1 6 VV C engine s - dismantlin g 12M3495 A 1 . Suitabl y identif y eac h solenoi d t o it s fitte d positio n an d not e th e angl e a t whic h i t i s positione d relativ e t o th e hydrauli c contro l unit . 2 . Remov e nu t fro m sleev e bolt , remov e an d discar d 'O ' ring . 3 . Remov e oute r so[...]

  • Página 196

    ENGIN E Hydrauli c contro l uni t - K1 6 VV C engine s - assemblin g ~ CAUTION : I t i s essentia l t o ensur e tha t /! absolut e cleanlines s i s maintaine d durin g th e followin g operations . 1 . Thoroughl y clea n al l components , dr y wit h compresse d air . 2 . Lubricat e ne w labyrint h seal s an d rac k sea l wit h engin e oil . 12M353[...]

  • Página 197

    ENGIN E Valve s - assemblin g M1 2 725 4 o jfb j 3 . 4 . 1 8 1 . Usin g 18 G 1577 , fi t ne w valv e ste m oi l seals . 2 . Lubricat e valv e stem s an d assembl e valves , usin g too l 18 G 151 9 an d adapte r 18 G 1519/1 , t o compres s valv e spring . ~ CAUTION : Valv e spring s ar e eithe r colou r /! code d o r plain , ensur e correc t sprin[...]

  • Página 198

    ENGIN E Camshaft s - K 8 an d al l K1 6 No n VV C engine s • refi t K 8 K1 6 1 . Lubricat e bearing s an d fi t camshaft(s ) an d positio n driv e pi n fo r 90 ° BTD C a s follows : K8 : Pi n a t 4 o'clock . K16 : Inle t pi n a t 4 o'clock . Exhaus t pi n a t 8 o'clock . Camshaf t carrie r an d oi l sea l - K 8 engine s - refi t 1[...]

  • Página 199

    ENGIN E 18G1769 A 12M0564 A A NOTE : Camshaf t fron t oi l sea l illustrated . 6 . Fi t oi l sea l protecto r 18 G 174 9 ove r en d o f camshaft . 7 . Fi t ne w camshaf t oi l seal s usin g too l 18 G 1769A . A NOTE : Fron t oi l seal s ar e coloure d BLACK , rea r oi l seal s ar e coloure d RED . ~ CAUTION : Oi l seal s mus t b e fitte d dry . D o[...]

  • Página 200

    ENGIN E ^ ^ NOTE : Camshaf t fron t oi l sea l illustrated . 5 . Positio n oi l sea l protecto r 18 G 174 9 ove r en d o f camshaf t 6 . Fi t ne w camshaf t oi l seal s usin g too l 18 G 1769A . A NOTE : Fron t oi l seal s ar e coloure d BLACK , rea r oi l seal s ar e coloure d RED . ~ CAUTION : Oi l seal s mus t b e fitte d dry . D o /! no t us [...]

  • Página 201

    ENGIN E (a/y <* > ill ) 6 . Positio n contro l shaf t i n camshaf t carrie r ensurin g tha t shaf t i s full y seate d i n journal s an d centr e o f slo t i n shaf t i s aligne d wit h cylinde r hea d matin g surfac e o f carrier . 7 . Positio n fron t an d rea r inle t camshaft s an d VV C assemblie s i n camshaf t carrie r a t th e sam e t[...]

  • Página 202

    ENGIN E 13 . Fi t 3 2 bolt s notin g tha t 4 longes t bolt s ar e fitte d a t eac h en d o f camshaf t carrier . 14 . Usin g sequenc e shown , progressivel y tighte n bolt s t o 1 0 Nm . 15 . Remov e timin g plate s 18 G 1770/ 1 - fron t an d 18 G 1770/ 2 - rear . 12M350 4 16 . 17 . Fi t an d tighte n ne w bolt s - fron t an d rea r VV C housing s [...]

  • Página 203

    ENGIN E 12M350 5 20 . Fi t rea r timin g bel t backplate , ti t an d tighte n bolt s to : M 5 bolt s - 6 N m M 6 bolt s -1 0 Nm . 12M3506 A 12M350 7 24 . Chec k tha t timin g slot s i n fron t an d rea r VV C contro l sleeve s ar e visibl e throug h hole s i n camshaf t carrier . CAUTION : I f timin g slot s ar e no t visible , / } carr y ou t fo[...]

  • Página 204

    26 . Usin g a screwdriver , rotat e contro l shaf t a s fa r a s possibl e i n a n anti-clockwis e direction , viewe d fro m fron t o f camshaf t carrier . A NOTE : Timin g slot s i n bot h VV C contro l sleeve s shoul d no w b e visible . 27 . Pus h hydrauli c contro l uni t pisto n t o to p o f bore . 28 . Fi t hydrauli c contro l unit , fi t an [...]

  • Página 205

    ENGIN E 33 . Fi t a ne w sealin g washe r t o oi l temperatur e transmitter , 34 . Fi t oi l temperatur e transmitte r an d tighte n t o 1 5 Nm . 35 . Thoroughl y clea n rea r timin g gears . 36 . Fi t rea r inle t camshaf t timin g gear , fi t bu t d o no t tighte n bolt . 37 . Fi t exhaus t camshaf t rea r timin g gear , fi t bu t d o no t tighte[...]

  • Página 206

    ENGIN E 41 . Restrai n eac h timin g gea r i n tur n usin g too l 12-18 2 an d tighte n bolt s t o 6 5 Nm . 4 3 4 2 18G157 0 4 2 42 . Temporaril y fi t fron t timin g gear s t o thei r respectiv e camshafts , rotat e gear s unti l timin g mark s o n al l 4 gear s ar e aligned , facin g inwards ; fi t too l 18 G 1570 . 43 . Chec k alignmen t o f eac[...]

  • Página 207

    ENGIN E Cylinde r hea d - K 8 an d K1 6 No n VV C engine s fitte d wit h a distributo r - refi t K8 CAUTION : I f crankshaf t ha s bee n rotated , /1 chec k tha t timin g mark s o n crankshaf t timin g gea r ar e aligne d wit h flang e o n oi l pum p an d tha t too l 18 G 157 1 i s lockin g flywheel . 1 . Chec k cylinde r hea d bolt s i n oi l ra[...]

  • Página 208

    ENGIN E K16 9 . Temporaril y fi t timin g gear s t o camshafts , fi t bu t d o no t full y tighte n bolts . A NOTE : Thi s wil l enabl e camshaft s t o b e rotate d i n orde r t o enabl e remainin g bolt s t o b e tightened . Early engines - bolt s 1 an d 2 Later engines fitted with modified camshafts:- bolt s 3 an d 4 _9 C I JB ( I )! ( 1 >3 ( [...]

  • Página 209

    ENGIN E 8R M 005 7 9 . Tighte n al l 1 0 cylinde r hea d bolt s progressivel y i n sequenc e show n l o 2 0 Nm . Us e a fel t ti p pe n an d mar k positio n o f radia l mar k o n eac h bol t head . Tighte n al l bolt s i n sequenc e show n throug h 180 ° Tighte n al l bolt s i n sequenc e show n throug h anothe r 180 ° an d alig n mark . CAUTION [...]

  • Página 210

    ENGIN E 12M203 7 8 . Tighte n cylinde r hea d bolt s progressivel y i n sequenc e show n t o 2 0 Nm . Us e a fel t ti p pe n an d mar k positio n o f radia l mar k o n eac h bol t head . Tighte n bolt s i n sequenc e show n throug h 180 ° Tighte n al l bolt s i n sequenc e show n a furthe r 180 ° an d alig n marks . Camshaf t cove r an d timin g [...]

  • Página 211

    ENGIN E Camshaf t cove r an d timin g gear s - K1 6 engine s no t fitte d wit h plu g to p coi l ignitio n syste m - refi t 1 . Clea n matin g surface s an d insid e o f camshaf t cover . I f necessary , was h oi l separato r element s i n suitabl e solven t an d blo w dry . 2 . Fi t ne w camshaf t cove r gaske t dry , t o camshaf t carrier , wit h[...]

  • Página 212

    ENGIN E M1 2 4946 A A NOTE : VV C camshaf t timin g mark s ar e show n i n th e inse t o n th e illustration . 10 . Non VVC engines: Usin g too l 12-182 , alig n camshaf t gea r timin g marks . 11 . VVC engines: Chec k tha t camshaf t gea r timin g mark s ar e stil l aligned , repositio n gear s i f necessar y usin g too l 12-182 . 12 . Fi t camsha[...]

  • Página 213

    ENGIN E 12-18 2 9 . Fi t camshaf t gear s t o thei r respectiv e camshaft s ensurin g tha t driv e gea r pin s ar e locate d i n correc t slo t i n driv e gears , hol d gear s usin g too l 12-182 , fi t an d tighte n bolt s t o 6 5 Nm . 10 . Usin g too l 12-182 , alig n camshaf t gea r timin g marks . 11 . Fi t camshaf t gea r lockin g too l 18 G 1[...]

  • Página 214

    ENGIN E 4 . Chec k correc t alignmen t o f timin g mark s o n crankshaf t gea r t o mar k o n oi l pump . 5 . Fi t an d adjus t a ne w camshaf t timin g belt . ~ CAUTION : K1 6 VV C engines: - Remov e an d /! discar d tensione r sprin g an d pilla r bol t o n completio n o f camshaf t timin g bel t adjustment . Distributo r - K 8 an d K1 6 no n V[...]

  • Página 215

    ENGIN E CYLINDE R HEA D BOLT S INSPECTIO N 1 . Retai n bolt s i n fitte d order . 2 . Was h al l bolts , wip e dr y an d lightl y oi l threads . Cylinde r hea d bolt s ma y b e re-use d provide d the y pas s on e o f th e followin g tests . Tes t wit h cylinde r hea d remove d 1 . Carefull y ente r cylinde r hea d bolt s i n thei r origina l fitte [...]

  • Página 216

    ENGIN E CRANKSHAFT , MAI N & BIG-EN D BEARING S Crankshaf t end-floa t - checkin g ~ CAUTION : Crankshaf t end-float mus t b e /j checke d an d recorde d prio r t o removin g cylinde r head . 8HM348 3 1 . Chec k crankshaf t end-float , usin g a DTI . Carefull y leve r agains t flywhee l an d pres s crankshaf t awa y fro m DTI , zer o DT I an [...]

  • Página 217

    ENGIN E Pressed steel sump 11 . Remov e an d discar d 1 4 bolt s securin g sum p t o bearin g ladder , (1 1 bolt s i f anti-beamin g bracke t suppor t i s removed) . 12 . Remov e sump . 13 . Releas e gaske t fro m sump . A NOTE : Gaske t ma y b e re-use d i f i n goo d conditio n Alloy sump 14 . Progressivel y slacke n the n remov e 1 4 bolt s secu[...]

  • Página 218

    ENGIN E 18 G 173 6 Big-en d bearing s - remov e 1 . Refi t crankshaf t timin g gea r an d pulley . 2 . Fi t pulle y bol t an d washer , lightl y tighte n bolt . 3 . Ensur e tha t cylinde r line r retaine r clamp s 18 G 173 6 an d nylo n nut s ar e fitte d an d tha t fee t o f clamp s d o no t protrud e ove r cylinde r line r bores . I t JoOSot^Ot t[...]

  • Página 219

    ENGIN E Crankshaf t - remov e 1 . Remov e big-en d bearings , cap s an d bearin g shells . 2 . Remov e piston s an d cylinde r liners . 3 . Usin g assistance , positio n cylinde r block , cylinde r hea d fac e downward s o n a smooth , clea n woode n surface . 4 . Workin g i n sequenc e shown , slacke n the n remov e 1 0 bolt s securin g bearin g l[...]

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    ENGIN E Crankshaf t • inspectio n 1 . Clea n join t surface s o n bearin g ladde r an d cylinde r bloc k usin g suitabl e solvent . D O NO T US E A META L SCRAPE R O N SEALIN G SURFACES . Blo w ou t crankshaf t an d bearin g ladde r oilways . 2 . Measur e tota l thicknes s o f thrus t washer s remove d an d compar e wit h new . Tota l thicknes s [...]

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    ENGIN E 8 4 OVERHAU L[...]

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    ENGIN E Mai n bearing s selectio n Main bearings size selection table Bearin g ladde r Crankshaf t mai n journal s Bearin g ladde r Grad e 1 Grad e 2 Grad e 3 Grad e A BLU E - BLU E RE D - BLU E RE D - RE D Grad e B BLUE-GREE N BLU E - BLU E RE D - BLU E Grad e C GREE N - GREE N BLU E - GREE N BLU E - BLU E Colou r cod e o n edg e o f bearin g Thic[...]

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    ENGIN E Big-en d bearing s selectio n 1 . Recor d big-en d journa l cod e letter s fro m crankshaf t rea r web . Firs t lette r i s Numbe r 1 big-en d bearing . Recor d big-en d bearin g bor e cod e number s - thi s wil l b e 5 , 6 o r 7 locate d o n th e connectin g ro d bearin g cap . 2 . Chec k crankshaf t big-en d journa l diameters : -1.1,1. 4[...]

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    ENGIN E Crankshaft , mai n an d big-en d bearing s - refi t 1 . Clea n al l sealan t surface s o n block , bearin g ladde r an d oi l rail . Us e foa m actio n gaske t remove r an d a plasti c scrape r - D O NO T US E A META L SCRAPE R O N SEALIN G SURFACES . Ensur e al l oilway s ar e clear . Examin e shoulde r locatio n o n eac h bi g en d bolt ,[...]

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    ENGIN E ^aizSEfUszfc* * ^ 8fl M 349 2 7 . Lubricat e mai n journal s wit h engin e oil . Fi t bearin g ladde r t o block , fi t bolt s ensurin g tha t flange d hea d bol t i s fitte d a t positio n 10 . Tighte n bolt s i n sequenc e show n t o 5 N m the n i n sam e sequenc e t o 3 0 Nm . ~ CAUTION : Wit h bearin g ladde r fitted , /{ crankshaf t [...]

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    ENGIN E Alloy sump 24 . Clea n sealin g surfac e o n sum p flang e usin g suitabl e solvent . 12M178 2 25 . Appl y a 2 m m wid e x 0.2 5 m m thic k continuou s bea d o f sealant , Par t Numbe r GU G 705963G M t o sum p flang e a s show n the n sprea d t o a n eve n fil m usin g a roller . ~ CAUTION : T o avoi d contamination , /j assembl y shoul [...]

  • Página 227

    ENGIN E 2 9 31 ^ 12M178 3 32 . Usin g sequenc e shown , tighte n 1 4 bolt s to : M 8 x 2 5 - 2 5 N m M 8 x 6 0 - 3 0 N m 12M178 4 26 . Scre w alignmen t pin s 18G174 4 int o ho!6 s shown . 27 . Carefull y lowe r sum p ove r pin s an d o n t o bearin g ladder . 28 . Fi t 2 bolt s int o hole s shown , tighte n t o 4 Nm . 29 . Fi t 1 0 bolt s int o [...]

  • Página 228

    ENGIN E All engines 37 . Remov e too l 18 G 1574 . 33 . Appl y a 1. 5 m m continuou s bea d o f sealant , Par t No . GA C 800 0 t o replacemen t oi l sea l a s shown . ~ CAUTION : D o no t appl y oi l o r greas e t o /! an y par t o f oi l sea l o r runnin g surfac e o f crankshaft . Sea l mus t b e fitte d immediatel y afte r applyin g sealant .[...]

  • Página 229

    ENGIN E PISTONS , RING S & CYLINDE R LINER S Piston s an d connectin g rod s - remov e 1 . Suitabl y identif y eac h pisto n assembl y wit h it s respectiv e cylinde r liner . 2 . Remov e big-en d bearings . 3 . Usin g assistance , positio n cylinde r bloc k o n it s side . ~ CAUTION : Ensur e tha t fee t o f cylinde r / j line r retaine r cl[...]

  • Página 230

    ENGIN E Piston s - inspectio n 1 . 2 . 3 . 4 . 5 . 6 . Chec k piston s fo r distortio n an d cracks . Measur e an d recor d pisto n diamete r a t righ t angl e t o gudgeo n pi n an d 8 m m fro m botto m o f skirt . Chec k pisto n diamete r wit h figure s given . Measur e an d recor d pisto n diamete r i n lin e wit h gudgeo n pi n hol e an d 8 m m [...]

  • Página 231

    ENGIN E Pisto n t o cylinde r line r bor e clearanc e - checkin g Pisto n ring s - refi t _ CAUTION : Ensur e tha t pisto n ring s ar e / fitte d t o pisto n fo r th e cylinder bor e i n whic h the y wer e checked . 12M363 8 1 . Startin g wit h numbe r 1 piston , inver t pisto n an d connectin g ro d an d wit h wor d FRON T o r arro w o n pisto [...]

  • Página 232

    ENGIN E Cylinde r liner s - inspectio n Late r 1. 8 engine s onl y A/ B 1 . Measur e wea r an d tape r i n tw o axe s 6 5 m m fro m to p o f cylinde r line r bore . 1. 1 an d 1.4 : RE D grad e A = 74.97 0 t o 74.98 5 m m BLU E grad e B = 74.98 6 t o 75.00 0 m m 1. 6 an d 1.8 : RE D grad e A = 80.00 0 t o 80.01 5 m m BLU E grad e B = 80.01 6 t o 80.[...]

  • Página 233

    ENGIN E Cylinde r liner s - remov e 1 . Remov e pistons . 2 . Remov e cylinde r line r clamp s 18 G 1736 . 3 . Usin g assistance , positio n cylinde r bloc k o n it s side . Cylinde r liner s - refi t A NOTE : T o enabl e cylinde r line r retaine r clamp s t o b e fitte d whe n liner s ar e inserte d i n cylinde r block , crankshaf t an d bearin g [...]

  • Página 234

    Piston s an d connectin g rod s - refi t 1 . Usin g assistance , suppor t bas e o f cylinde r bloc k o n 2 woode n blocks . 2 . Ensur e tha t cylinde r line r retaine r clamp s 18 G 173 6 ar e fitte d an d tha t fee t o f clamp s d o no t protrud e ove r cylinde r line r bores . 3 . Lubricat e cylinde r bores , piston s an d rings wit h engin e oil[...]

  • Página 235

    ENGIN E DAT A Oi l pum p Oute r roto r t o housin g clearanc e Inne r roto r ti p clearanc e Roto r en d floa t Relie f valv e sprin g fre e lengt h Coolin g syste m Thermosta t start s t o ope n Nomina l settin g Thermosta t full y ope n Camshaft s Camshaf t end-floa t - K 8 an d K f 6 No n W C engines : - Servic e limi t Camshaf t end-floa t - K1[...]

  • Página 236

    ENGIN E Valv e spring s K8 engines Fre e lengt h Fitte d lengt h Loa d - valv e close d Loa d - valv e ope n 46. 2 m m 37. 0 m m 25 5 ± 1 2 N 53 5 ± 2 0 N K16 Non VVC engines Fre e lengt h Fitte d lengt h Loa d - valv e close d .. . Loa d - valv e ope n 50. 0 m m 37. 0 m m 25 0 ± 1 2 N 45 0 ±1 8 Na t 28. 8 m m K16 VVC engines Fre e lengt h 47. [...]

  • Página 237

    ENGIN E Valv e guide s Fitte d height : K 8 engine s 10. 3 m m K1 6 engine s 6. 0 m m Valv e seat s Angl e . . 45 ° Widt h No t tripl e angl e valv e seat s : - Inle t an d exhaus t . . 1. 5 m m Tripl e angl e valv e seat s : - Inle t 1. 0 t o 1. 4 m m Exhaus t 1. 4 t o 1. 8 m m Valv e fac e angle : Inle t 45 ° Exhaus t 45 ° Crankshaf t Cranksha[...]

  • Página 238

    ENGIN E Pisto n ring s Ne w rin g t o groov e clearance : K8 and K16 -1.1 and 1.4 To p compressio n ring 0.0 4 t o 0.0 8 m m 2n d compressio n ring 0.0 3 t o 0.06 2 m m Oi l contro l rail s 0.04 4 t o 0.05 5 m m K16-1.6 and 1.8 To p compressio n ring 0.04 0 t o 0.07 2 m m 2n d compressio n ring 0.03 0 t o 0.06 2 m m Oi l contro l rail s 0.01 0 t o [...]

  • Página 239

    TORQU E WRENC H SETTING S Ai r cleane r suppor t bracke t bolt s . 1 0 N m Allo y sum p bolts * M 8 x 2 5 2 5 N m M 8 x 6 0 3 0 N m Bearin g ladde r t o bloc k bolts * 3 0 N m Big-en d bolt s 20N m + ^ Blankin g plat e t o camshaf t carrie r bolts : No t plu g to p coi l ignitio n system : . 2 5 N m Plu g to p coi l ignitio n system : - Inle t cams[...]

  • Página 240

    ENGIN E Rea r timin g bel t backplat e screw s - K1 6 VV C engines : M 5 6 N m M 6 1 0 N m Rea r timin g bel t cove r screw s - K1 6 VV C engine s . . 1 0 N m Rea r timin g gea r bolt s - K1 6 VV C engine s 3 5 N m R H engin e mountin g bracke t bolt s 4 5 N m Roto r ar m scre w 1 0 N m Sparkplug s 2 5 N m Spar k plu g cove r screw s 1 0 N m Thermo[...]

  • Página 241

    ENGIN E Pisto n Rin g Clam p K1 6 VV C Housin g Oi l Sea l Remove r Centr e Bol t Valv e Lifte r Basi c Too l Valv e Lifte r Adapto r Camshaf t Lockin g Too l Flywhee l Lockin g Too l - Flywhee l No t Fitte d Wit h Relucto r Rin g Crankshaf t Rea r Oi l Sea l Replace r Too l Valv e Guid e Remover/Replace r Dept h Gaug e - Al l K1 6 Engine s Nylo n [...]

  • Página 242

    Lotu s Servic e Note s Sectio n EM N ENGIN E MANAGEMEN T & FUE L INJECTIO N SECTIO N EM N - M11 1 ELIS E Sectio n Pag e Introductio n & Componen t Locatio n EMN. 1 3 "Lotu s Check ' Scanne r Too l EMN. 2 4 Throttl e Cabl e Adjustmen t EMN. 3 7 Electroni c Contro l Modul e (ECM ) EMN. 4 7 Rela y Modul e EMN. 5 8 Manifol d Absolut e[...]

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    Lotu s Servic e Note s Sectio n EM N COMPONEN T LOCATIO N DIAGRA M Pag e 2 200 0 / 0 1[...]

  • Página 244

    Lotu s Servic e Note s Sectio n EM N EMN. 1 - INTRODUCTIO N Ke v t o ComDonen t Locatio n Diaara m 1 . Fue l pum p 14 . Ca m angl e senso r (W C only ) 2 . Engin e coolan t temperatur e (ECT ) senso r 15 . Idl e ai r contro l (IAC ) valv e 3 . Wate r temperatur e gaug e sende r (vertical ) 16 . Throttl e postio n (TP ) senso r 4 . Crankshaf t posit[...]

  • Página 245

    paire d wit h 4 , an d 2 wit h 3) , th e spar k i n th e cylinde r o n th e exhaus t strok e bein g 'wasted' . Th e twi n coi l pac k i s mounte d o n th e cylinde r bloc k a s fo r standar d engines . O n W C engines , th e variabl e valv e contro l mechanis m i s als o controlle d b y th e ECM . Tw o solenoi d valve s attache d t o th e[...]

  • Página 246

    Lotu s Servic e Note s Sectio n EM N Adaptor harness plugged into DLC & switched to •MEMS' Power harness MEMS 1.9 or MEMS 2J programme card Printer Connect to battery Scanner tool lemfM I T o Connec t 'Lotu s Check ' T o connec t th e equipment , procee d a s follows : i) . Plu g th e powe r harnes s int o th e scanne r too l a[...]

  • Página 247

    Lotu s Servic e Note s Sectio n EM N test . Ru n a furthe r tes t t o verif y th e repair . Em. Th e 'programme ' men u i s availabl e onl y o n th e MEM S 2 J card , an d allow s matchin g o f th e engin e managemen t an d securit y 5A S module s i f on e o r th e othe r i s replaced . A t th e instan t o f ignitio n i s switc h on , th [...]

  • Página 248

    Lotu s Servic e Note s Sectio n EM N EMN. 3 • THROTTL E CABL E ADJUSTMEN T Befor e adjustin g th e cable , firs t chec k tha t th e peda l en d o f th e cabl e i s correctl y located , an d tha t th e cabl e i s correctl y route d wit h n o shar p bend s o r entrapment . D o no t attemp t t o adjus t th e throttl e cabl e o r idl e spee d b y mea[...]

  • Página 249

    Lotu s Servic e Note s Sectio n EM N Befor e removin g a n ECM , firs t disconnec t th e batter y eart h lea d befor e pressin g th e retainin g bar b an d unpluggin g th e harnes s connector(s) . O n standar d cars , th e MA P senso r i s containe d withi n th e EC M body , wit h th e senso r hos e connectin g t o a spigo t o n th e undersid e o f[...]

  • Página 250

    Lotu s Servic e Note s Sectio n EM N MN. 6 - MANIFOL D ABSOLUT E PRESSUR E (MAP I SENSO R Th e MA P signa l i s fundamenta l t o th e calculatio n o f ai r consumptio n an d fue l calibration . Th e EC M provide s a 5 vol t suppl y an d eart h pat h t o th e sensor , whic h return s a voltag e representin g th e manifol d pressure . O n standar d e[...]

  • Página 251

    Lotu s Servic e Note s Sectio n EM N EMN. 7 - CRANKSHAF T POSITIO N SENSO R Th e signal s provide d b y th e crankshaf t positio n senso r enabl e th e EC M t o determine : engin e speed ; crankshaf t position . Th e inductiv e typ e senso r i s mounte d b y a singl e fixin g int o a flang e a t th e right han d rea r o f th e cylinde r block , whe[...]

  • Página 252

    Lotu s Servic e Note s Sectio n EM N EMN. 8 • ENGIN E COOLAN T TEMPERATUR E fECT ) SENSO R Th e EC M require s a coolan t temperatur e inpu t signa l i n orde r t o increas e fue l deliver y an d maintai n driveabilit y durin g th e col d runnin g an d warm-u p phase . Th e signa l fro m thi s senso r i s use d fo r man y differen t parameter s w[...]

  • Página 253

    Lotu s Servic e Note s Sectio n EM N EMN. 9 - INTAK E AI R TEMPERATUR E MA ~ n SENSO R Th e intak e ai r temperatur e (IAT ) senso r i s fitte d int o th e inle t manifol d trac t o f no. 4 cylinder , an d i s a transduce r wit h a negativ e temperatur e coefficient , suc h tha t it s electrica l resistanc e reduce s wit h increasin g temperature .[...]

  • Página 254

    Lotu s Servic e Note s Sectio n EM N EMN. 8 - ENGIN E COOLAN T TEMPERATUR E fECT ) SENSO R Th e EC M require s a coolan t temperatur e inpu t signa l i n orde r t o increas e fue l deliver y an d maintai n driveabilit y durin g th e col d runnin g an d warm-u p phase . Th e signa l fro m thi s senso r i s use d fo r man y differen t parameter s wit[...]

  • Página 255

    Lotu s Servic e Note s Sectio n EM N EMN. 9 - INTAK E AI R TEMPERATUR E (IAT SENSO R Th e intak e ai r temperatur e (IAT ) senso r i s fitte d int o th e inle t manifol d trac t o f no. 4 cylinder , an d i s a transduce r wit h a negativ e temperatur e coefficient , suc h tha t it s electrica l resistanc e reduce s wit h increasin g temperature . [...]

  • Página 256

    Lotu s Servic e Note s Sectio n EM N EMN.1 0 - THROTTL E POSITIO N (TP ) SENSO R Th e throttl e positio n (TP ) senso r i s a potentiomete r fitte d directl y t o th e en d o f th e throttl e spindle , an d provide s th e EC M wit h informatio n o n bot h throttl e opening , an d rat e o f chang e o f throttl e opening . Fo r example , whe n a full[...]

  • Página 257

    EMN.1 1 - IDL E AI R CONTRO L flAC ) VALV E Th e idl e ai r contro l (IAC ) valv e i s mounte d o n th e intak e plenum , an d control s a n ai r passag e whic h by - passe s th e throttl e valve . Whe n th e pintl e o f th e valv e i s full y extended , th e passag e i s close d of f for a minimu m idl e speed , bu t a s th e EC M command s th e I[...]

  • Página 258

    Lotu s Servic e Note s Sectio n EM N EMN.1 2 - OXYGE N (O d SENSO R Th e MEM S syste m operate s a 'close d loop ' fue l contro l syste m whereb y th e outpu t signa l fro m a n oxyge n senso r i n th e exhaus t syste m i s monitore d b y th e ECM , whic h constantl y adjust s th e air/fue l rati o t o tha t providin g th e mos t efficien[...]

  • Página 259

    • EMN.1 3 - CAMSHAF T POSITIO N SENSO R (W C version s only ) Th e camshaf t positio n senso r ha s tw o functions : i ) t o provid e a n engin e positio n referenc e fo r th e sequen - tia l injection ; ii ) t o measur e th e actua l inle t ca m perio d a s controlle d b y th e W C mechanism . Th e inductiv e typ e senso r i s mounte d o n th e [...]

  • Página 260

    Lotu s Servic e Note s Sectio n EM N EMN.1 4 - W C MECHANIS M CONTRO L SOLENOID S Th e inle t ca m perio d i s determine d b y a hydrauli c contro l uni t (HCU ) mounte d o n th e righ t han d fron t o f th e cylinde r head . Th e HC U use s tw o solenoid s t o operat e a spoo l valv e an d contro l a pisto n an d rac k mechanism , whic h output s [...]

  • Página 261

    Lotu s Servic e Note s Sectio n EM N EMN.1 5 - OI L TEMPERATUR E SENSO R A n oi l temperatur e senso r i s mounte d i n th e to p o f th e W C hydrauli c contro l unit . Th e oi l temperatur e i s use d b y th e EC M t o determin e ho w quickl y th e W C mechanis m wil l respon d t o ca m perio d chang e com - mands . T o replac e th e sensor , unp[...]

  • Página 262

    EMN.1 6 - FUE L SYSTE M Th e fue l syste m i s a hig h pressur e recirculatin g type , usin g a n 'i n tank ' submerge d 3-stag e impelle r pump , a n i n lin e caniste r filter , a commo n fue l rai l supplyin g al l fou r injectors , an d a fue l pressur e regulatin g valv e controllin g th e retur n lin e t o th e tank . WARNING : Th e[...]

  • Página 263

    Lotu s Servic e Note s Sectio n EM N Fuel filler neck Fuel filter Filler breather hose Fuel pressure regulator valve Fuel pump Fuel rail Fuel injector Fuel feed line Fuel return line Fue l Pum p Switchin g Th e fue l pum p i s controlle d b y th e EC M vi a th e fue l pum p rela y locate d i n th e rela y module , an d i s energise d unde r th e fo[...]

  • Página 264

    • functio n o f th e regulato r i s t o maintai n a constan t pressur e differentia l acros s th e injector s a t al l times , i.e . a constan t differenc e betwee n fue l pressur e supplie d t o th e injector , an d inle t manifol d pressur e a t th e por t injecto r nozzle . B y usin g a n intak e plenu m pressur e signa l t o supplemen t regul[...]

  • Página 265

    Lotu s Servic e Note s Sectio n EM N Pus h Fi t Connector s Th e fue l rai l fee d an d retur n hose s ar e equippe d wit h pus h fi t connector s t o allo w eas y powertrai n re - moval . Th e fee d lin e connecto r i s colou r code d orange , an d th e retur n lin e connecto r green . Not e tha t th e fee d lin e shoul d no t b e opene d withou t[...]

  • Página 266

    Lotu s Servic e Note s Sectio n EM N Fue l Rai l an d Pressur e Regulato r Valv e - Replacemen t D o no t attemp t t o remov e th e pressur e regulato r valv e fro m th e fue l rail ; Th e valv e i s supplie d onl y a s a n assembl y wit h th e rail . Th e fue l rai l i s remove d fro m th e engin e complet e wit h th e fou r fue l injectors . 1 . [...]

  • Página 267

    8 . T o remov e a n injecto r fro m th e rail , unplu g th e harnes s connector , remov e th e clip , an d withdra w th e injecto r fro m th e rail . Discar d th e tw o 'O ' rings . 9 . Befor e re-fittin g th e injector s an d rail , clea n th e injecto r recesse s i n th e rai l an d inle t manifold , an d fi t eac h injecto r wit h 2 ne[...]

  • Página 268

    Lotu s Servic e Note s Sectio n EM N Distributo r A roto r ar m i s mounte d o n a 'D ' shape d extensio n t o th e rea r en d o f th e inle t camshaft , an d i s retaine d b y a patchloc k screw . Always replace the screw, or retreat with Loctite 242. Th e roto r ar m incorporate s a sup - presso r an d ha s a resistanc e valu e o f 1.2 [...]

  • Página 269

    Lotu s Servic e Note s Sectio n F H TRANSMISSIO N SECTIO N F H - M11 1 ELIS E Sub-Sectio n Pag e Introductio n FH. 1 2 Gearchang e Mechanis m FH. 2 2 Lubricatio n FH. 3 6 Driveshaft s FH. 4 6 Transmissio n Replacemen t FH. 5 1 0 Transmissio n Overhau l & Specia l Tool s FH. 6 1 1 Paq e 1[...]

  • Página 270

    Lotu s Servic e Note s Sectio n HE FH. 1 - INTRODUCTIO N Th e transmissio n assembl y i s a n 'en d on ' type , mounte d o n th e lef t han d en d o f th e engin e unit , an d comprise s o f th e clutc h housing , fiv e spee d gearbox , fina l driv e gears , an d differential . Th e uni t i s supplie d b y Rover , an d i s designate d &ap[...]

  • Página 271

    Lotu s Servic e Note s Sectio n HE Gear lever Gear lever crossgate bellcrank Crossgate movement Fore/aft movement Gear select cable Transmission selector shaft Transmission crossgate bellcrank Cable front abutments Crossgate cable Cable rear abutment Selector shaft lever Gearchang e Cabl e Adjustmen t Bot h gearchang e cables , crossgat e an d se[...]

  • Página 272

    Lotu s Servic e Note s Sectio n HE Crossgat e position : Viewe d fro m behind , th e gea r leve r shoul d b e vertical . I f nec - essary , adjus t th e lengt h o f th e transmis - sio n en d bellcran k ti e rod . Th e nomina l lengt h betwee n bal l join t centre s i s 7 0 mm . Th e ti e ro d i s R H threade d a t bot h ends , s o tha t befor e a [...]

  • Página 273

    Lotu s Servic e Note s Sectio n HE leve r pivo t an d crossgat e spigo t bush , an d withdra w th e housin g an d gea r leve r assembly . T o re-assemble : Fi t th e pivo t socke t gaske t int o th e gea r leve r housing , followe d b y th e to p (smaller ) sectio n o f th e pivo t socket . Appl y Do w Cornin g Molykot e 3 3 Mediu m silicon e greas[...]

  • Página 274

    Lotu s Servic e Note s Sectio n HE Gearchang e Cabl e Replacemen t Fo r acces s t o th e gea r cables , th e gea r leve r shrou d an d parkin g brak e leve r tri m mus t b e removed : Unscre w th e gea r leve r knob , remov e th e singl e scre w eac h sid e o f th e shroud , an d withdra w th e shroud . Remov e th e singl e scre w securin g th e pa[...]

  • Página 275

    Lotu s Servic e Note s Sectio n HE Th e inboar d C.V . join t i s equippe d wit h a mal e spline d spigo t shaf t whic h engage s wit h th e femal e spline s o f th e differentia l outpu t su n gear , an d i s retaine d b y a roun d sectio n sprin g circli p o n it s end . Eac h o f th e tw o transmissio n outpu t oi l seal s run s o n a steppe d s[...]

  • Página 276

    Driveshaf t Replacemen t Removin g a driveshaf t fro m th e transmissio n wil l resul t i n som e los s o f transmissio n lubricant . I t ma y b e preferre d t o drai n of f som e oi l vi a th e transmissio n drai n plu g beforehand . 1 . Remov e th e transmissio n drai n plu g an d drai n of f approximatel y 1 litr e o f oi l int o a clea n contai[...]

  • Página 277

    Lotu s Servic e Note s Sectio n HE Pres s th e C.V . join t int o th e differentia l gea r spline s unti l a 'click ' indicate s tha t th e circli p ha s engage d i n it s location . Pul l o n th e bod y o f th e join t t o chec k security . 10 . Fi t th e oute r en d o f th e shaf t int o th e hub , an d retai n wit h th e nut . 11 . Ref[...]

  • Página 278

    Lotu s Servic e Note s Sectio n HE th e insid e o f th e ne w boot . NOTE : Th e greas e provide d i n th e kit s i s speciall y formulate d fo r wea r resistanc e an d durability . D O NO T us e substitute s o r mi x wit h othe r lubricants . 9 . Inboar d Joint : I f re-fittin g a cleane d ou t joint , pac k th e join t wit h tw o o f th e greas e[...]

  • Página 279

    Lotu s Servic e Note s Sectio n HE 10 . Suppor t th e weigh t o f th e transmissio n assembl y befor e removin g th e L H engin e (transmission ) mountin g an d bracket . 11 . Remov e th e si x bolt s securin g th e clutc h housin g t o th e engine : - 2 bolt s t o th e sump ; - 1 bol t eac h sid e throug h th e bloc k lowe r 'wings' ; - [...]

  • Página 280

    PG1 Manual Gearbox Overhaul Manual PG1 Handgeschakelde versnellingsbakrevisiehandboek PG1 Boite de vitesses manuelle Manuel de revision PG1 Schaltgetriebe Uberholungsanleitung PG1 Cambio meccanico Manuale di revisione PG1 Caja de cambios manual Manual de revisidn PG1 Caixa de velocidades manual Manual de revisao RCL012 4[...]

  • Página 281

    PG 1 MANUA L GEARBO X OVERHAU L MANUA L Thi s gearbo x i s fitte d t o th e followin g models: - Rove r 218/41 8 Diese l Ne w Rove r 20 0 Diese l Ne w Rove r 21 8 Ne w Rove r 40 0 Diese l Rove r 22 0 Rover42 0 Rove r 60 0 Diese l Rove r 60 0 T i Rove r 82 0 Rove r 80 0 KV 6 MG- F Publicatio n Par t No . RC L 012 4 EN G (2n d edition ) Publishe d b [...]

  • Página 282

    INTRODUCTIO N INTRODUCTIO N Ho w t o us e thi s manua l Dimension s T o assis t i n th e us e o f thi s manua l th e sectio n titl e i s give n a t th e to p an d th e relevan t sub-sectio n i s give n a t th e botto m o f eac h page . Thi s manua l contain s procedure s fo r th e overhau l o f th e gearbo x o n th e benc h wit h th e engin e remov[...]

  • Página 283

    INTRODUCTIO N SPECIFICATIO N Rove r ar e constantl y seekin g t o improv e th e specification , desig n an d productio n o f thei r vehicle s an d alteration s tak e plac e accordingly . Whil e ever y effor t ha s bee n mad e t o ensur e th e accurac y o f thi s Manual , i t shoul d no t b e regarde d a s a n infallibl e guid e t o curren t specifi[...]

  • Página 284

    MANUA L GEARBO X CONTENT S Pag e DESCRIPTIO N AN D OPERATIO N GEARBO X COMPONENT S 3 SECTIONE D VIE W O F GEARBO X 4 DESCRIPTIO N 5 DESCRIPTIO N - TORSE N DIFFERENTIA L 5 OPERATIO N 5 OPERATIO N - TORSE N DIFFERENTIA L 6 DESCRIPTIO N - REVERS E BRAK E 8 OPERATIO N - REVERS E BRAK E 9 OVERHAU L GEARBO X DISMANTLIN G 1 COMPONEN T DISMANTLIN G 8 Inpu [...]

  • Página 285

    MANUA L GEARBO X Thi s pag e i s intentionall y lef t blan k DESCRIPTIO N AN D OPERATIO N REVISED:[...]

  • Página 286

    MANUA L GEARBO X 37M129 7 DESCRIPTIO N AN D OPERATIO N REVISED :[...]

  • Página 287

    MANUA L GEARBO X 39 . Needl e rolle r bearin g - 2n d gea r 40 . 2n d gea r 41 . 3r d gea r 42 . 4t h gea r 43 . 5t h gea r 44 . Bal l bearin g - outpu t shaf t 45 . Bai l bearin g - outpu t shaf t 46 . Tongue d washe r 47 . Outpu t shaf t nu t - L.H . threa d 48 . Circli p 49 . Revers e idle r shaf t 50 . Thrus t washe r - revers e idle r gea r 51[...]

  • Página 288

    MANUA L GEARBO X 37M116 2 SECTIONE D VIE W O F GEARBO X 1 . Oi l guid e plat e 2 . Inpu t shaf t assembl y 3 . Gea r cas e 4 . Revers e idle r shaf t bol t 5 . Revers e idle r gea r 6 . Breathe r pip e an d bracke t 7 . Differentia l housin g 8 . Acces s plu g - outpu t shaf t bearin g circli p 9 . Outpu t shaf t assembl y 10 . Shif t ar m assembl [...]

  • Página 289

    MANUA L GEARBO X DESCRIPTIO N Th e 5 spee d constan t mes h gearbo x employ s singl e helica l gear s fo r spee d transmissio n an d fina l drive . Th e inpu t shaf t carrie s th e primar y inpu t gear , revers e pinion , 2n d gea r an d 3rd , 4t h an d 5t h gea r synchromes h hub s an d idle r gears . I t i s supporte d b y tw o ballraces . En d f[...]

  • Página 290

    MANUA L GEARBO X OPERATIO N - TORSE N DIFFERENTIA L Torse n differentia l - Typ e A - Seria l numbe r prefixe s K4B X an d K7BSU T 1 . Helica l sid e gea r 2 . Elemen t gea r assembl y - wor m an d spu r gear s 3 . Journa l pi n 4 . Thrus t washe r an d spacin g washe r 5 . Tw o thrus t washer s an d needl e rolle r bearin g 6 DESCRIPTIO N AN D OPE[...]

  • Página 291

    MANUA L GEARBO X Torse n differentia l - Typ e B - Seria l numbe r prefixe s C6FTUT ; W4DTUT ; C6DTUTan d C6DTUT H 1 . Helica l sid e gea r 2 . Elemen t gea r assembl y - helica l gear s 3 . Frictio n washer s 4 . Thrus t washer s Unlik e a conventiona l limite d sli p differential , th e torqu e sensin g differentia l doe s no t rel y o n th e loc[...]

  • Página 292

    MANUA L GEARBO X DESCRIPTIO N - REVERS E BRAK E A revers e brak e mechanis m ha s bee n introduce d t o th e PG- 1 gearbox , an d i s operate d b y th e selecto r for k mechanism , whic h stop s th e inpu t shaf t fro m rotatin g prio r t o th e engagemen t o f revers e gea r an d provide s a quie t an d smoot h engagemen t o f revers e gear , prov[...]

  • Página 293

    MANUA L GEARBO X OPERATIO N - REVERS E BRAK E Whe n selectin g revers e gear , th e 5th/revers e shif t piec e (1 ) move s upwards , an d th e angle d fac e o f th e loc k plat e (3 ) contact s th e ram p o f 3rd/4t h selecto r for k (2) . Th e upwar d movemen t carrie s th e loc k plat e (3 ) outward s unti l i t contact s th e abutmen t (4 ) o n [...]

  • Página 294

    B 37M114 7 Slid e 5th/revers e gea r selecto r of f 5th/revers e selecto r shaft . Slid e 3rd/4t h an d 5t h selecto r fork s of f 5th/revers e selecto r shaft . 3 . 3rd/4t h gea r selecto r for k 4 . 5t h gea r selecto r for k 5 . 5th/revers e selecto r shaf t 6 . 1 st/2n d gea r selecto r for k 7 . 1st/2n d selecto r shaf t Selecto r Shaf t Compo[...]

  • Página 295

    MANUA L GEARBO X 5th/Revers e Selecto r - wit h revers e brak e Th e 5th/revers e selecto r (1 ) i s secure d t o th e selecto r shaf t b y a rol l pi n (2) . Th e selecto r incorporate s th e component s fo r th e revers e brak e operation . Thi s comprise s o f a loc k plat e (3 ) a retainin g sprin g (4) . Th e sprin g retain s th e loc k plat e[...]

  • Página 296

    MANUA L GEARBO X Differentia l Assembl y 1 . Chec k gea r teet h fo r wear , chippin g an d sign s o f overheating . ~ CAUTION : I t i s no t possibl e t o overhau l / j Torse n differentials . Replac e complet e assembl y i f an y o f th e abov e ar e apparent . Torsen differential 2 . Chec k speedomete r driv e gea r fo r damage , replac e i f [...]

  • Página 297

    MANUA L GEARBO X Refit 4 . Inner bush: Usin g too l 18 G 1723-1 , drif t inne r bus h int o differentia l housing . 5 . Outer bush: Usin g too l 18 G 1723-2 , drif t oute r bus h int o differentia l housing . A CAUTION : Ensur e en d o f too l 18 G 1723- 2 /! i s locate d i n inne r bush . 6 . Gearboxes fitted with output shaft bearing retainer p[...]

  • Página 298

    MANUA L GEARBO X Synchr o Assemblie s 1 . Assembl e eac h synchr o sleev e t o it s respectiv e hu b ensurin g tha t raise d teet h o n th e sleev e ar e aligne d wit h th e deepe r groove s i n hub . 2 . Fi t sprin g ring s t o retai n hub . NOTE : Onl y on ® sprin g rin g s s fitte d o n 5t h spee d synchro . 3 . Assembl e synchr o ring s t o th[...]

  • Página 299

    MANUA L GEARBO X Selecto r Shaft s 1 . Slid e 5t h an d 3rd/4t h selecto r fork s o n t o 5th/revers e selecto r shaft . « CAUTION : Ensur e tha t longes t portio n o f /j selecto r for k lug s fac e awa y fro m shoulde r o f shaft . 2 . Slid e 5th/revers e selecto r o n t o 5th/revers e selecto r shaft ; secur e selecto r wit h a ne w rol l pin[...]

  • Página 300

    MANUA L GEARBO X Differentia l Pinio n Gea r Backlas h - Chec k an d Adjus t 10 . Selec t circlip(s ) fro m size s availabl e whic h equa l thicknes s required . Fourtee n circlip s ar e availabl e rangin g fro m 0 . 5 m m t o 1.1 5 m m thic k i n increment s o f 0.0 5 mm . ^ CAUTION : N o mor e tha n tw o circlip s ma y /! b e fitted , i t i s n[...]

  • Página 301

    MANUA L GEARBO X Standard and Torsen differentials: 9 . Fi t fina l driv e gea r t o carrie r ensurin g referenc e mark s ar e aligned . 10 . Fi t 1 0 bolt s an d tighte n progressivel y t o 11 0 Nm . Differentia l Bearin g Pre-loa d - Chec k an d Adjus t 1 . Positio n origina l selectiv e circli p i n gea r case . 2 . Positio n differentia l assem[...]

  • Página 302

    MANUA L GEARBO X GEARBO X ASSEMBLIN G 1 . Lightl y lubricat e al l component s wit h gearbo x oil . 2 . Usin g a suitabl e piec e o f tubing , fi t a ne w selecto r shaf t oi l seal . housin g usin g tool s 18G135 4 an d 18 G 1354-5 . NOTE : Dependin g o n application , outpu t shaf t bearin g ma y hav e oi l hole s drille d I n bearin g cage : the[...]

  • Página 303

    MANUA L GEARBO X 18 G 1354-1 6 37M114 5 ~ CAUTION : Differentia l oi l seals : Typ e A ar e / j fitte d wit h earl y driv e shafts . Typ e B oi l seal s ar e fitte d t o late r driv e shafts . Th e late r oi l seal s ar e waxe d an d mus t b e fitte d dry . Ensur e tha t replacemen t seal s ar e th e sam e typ e a s thos e removed . 7 . Fi t a ne[...]

  • Página 304

    MANUA L GEARBO X -18 G 135 4 18 G 135 4 -1 6 32 . 33 . 34 . 35 . 36 . 37 . 38 . 39 . 40 . 41 . 42 . 43 . Positio n gea r cas e ove r differentia l housin g keepin g gea r cas e squar e t o housing . Lowe r gea r cas e int o positio n an d a t th e sam e time , expan d outpu t shaf t bearin g circli p usin g too l 18 G 1392 . Pus h gea r cas e full [...]

  • Página 305

    Lotu s Servic e Note s Sectio n EMN WHEEL S & TYRE S SECTIO N G F - M11 1 ELIS E Sub-Sectio n Paa e Genera l Descriptio n GF. 1 2 Winte r Tyre s & Sno w Chain s GF. 2 4 Emergenc y Puncture d Tyr e Inflato r GF. 3 4 Securit y Wheelnut s GF. 4 5 2000 / (11 Pag e 1[...]

  • Página 306

    GF. 1 - GENERA L DESCRIPTIO N Th e singl e piece , ligh t allo y roadwheels , i n variou s styles , ar e fitte d wit h Pirell i P Zer o tyres , engineere d t o provid e th e optimu m balanc e o f rid e an d handlin g characteristics . Pirell i P Zer o ar e th e recommende d tyre s fo r us e o n th e vehicl e unde r norma l roa d conditions . I n or[...]

  • Página 307

    Lotu s Servic e Note s Sectio n EMN Not e tha t th e inse t figur e i s th e offse t o f th e wheelri m centrelin e reletiv e t o th e wheel/hu b mountin g face . A positiv e figur e indicate s tha t th e wheelri m centrelin e lie s inboar d o f th e whee l mountin g face , wherea s a negativ e fig - ur e mean s th e wheelri m centrelin e i s outbo[...]

  • Página 308

    Lotu s Servic e Note s Sectio n G F GF. 2 - WINTE R TYRE S & SNO W CHAIN S I f th e ca r i s t o b e use d i n ver y col d territories , o r drive n o n sno w covere d roads , i t i s recommende d t o fit winte r tyre s develope d specificall y fo r suc h conditions . Lotu s approve s th e fitmen t o f Micheli n X M+ S 13 0 winte r tyre s i n t[...]

  • Página 309

    Lotu s Servic e Note s Sectio n EMN 4 . Immediatel y driv e fo r 6 -1 2 mile s (10-2 0 km ) (o r t o th e tyr e depo t i f nearer ) i n a moderat e manne r an d no t exceedin g 3 0 mp h (4 5 km/h) , t o allo w th e sealan t t o spread . The n chec k an d adjus t th e tyr e pressur e a s necessary . 5 . Hav e th e tyr e professionall y repaire d o r[...]

  • Página 310

    Lotu s Servic e Note s Sectio n H E STEERIN G SECTIO N H E - M11 1 ELIS E Genera l Descriptio n Steerin g Whee l Uppe r Colum n Assembl y Intermediat e Colum n Fron t Whee l Alignmen t & Rac k Gaiter s Rac k & Pinio n Assembl y Removal/Replacemen t Adjustmen t o f Rac k Ba r Thrus t Pa d Sub-Sectio n Pag e HE. 1 2 HE. 2 2 HE. 3 4 HE. 4 7 HE[...]

  • Página 311

    D Lotu s Servic e Note s Sectio n JH Upper column HE. 1 - GENERA L DESCRIPTIO N Th e steerin g syste m o f th e Elis e comprise s a telescopicall y collapsibl e uppe r colum n assembly , connect - in g t o a rigidl y mounte d rac k an d pinio n assembl y vi a a universall y jointe d intermediat e shaft . Th e steerin g rac k ti e rod s connec t t o[...]

  • Página 312

    D Lotu s Servic e Note s Sectio n JH T o allo w acces s fo r a steerin g whee l pulle r tool , i t i s necessar y firs t t o remov e th e colum n shroud : Releas e th e fou r screw s securin g th e shrou d uppe r section , turnin g th e steer - in g whee l a s necessar y t o permi t access . Pul l ou t th e gromme t fro m aroun d th e ignitio n swi[...]

  • Página 313

    D Lotu s Servic e Note s Sectio n JH 1 . Se t th e fron t whee l alignmen t t o specificatio n wit h equa l trac k ro d length s (se e sub-sectio n CG.2) . 2 . Tur n th e steerin g t o eac h ful l loc k i n tur n an d se t th e steerin g whee l o n th e colum n spline s suc h tha t it s orientatio n i n on e ful l loc k positio n i s th e neares t [...]

  • Página 314

    D Lotu s Servic e Note s Sectio n JH Th e uppe r steerin g colum n assembl y comprise s a n inne r colum n whic h connect s th e steerin g whee l t o th e intermediat e shaft , an d a tubula r stee l oute r colum n which , wit h it s allo y uppe r bearin g housing , support s th e inne r colum n an d carrie s th e colum n lever switche s fo r light[...]

  • Página 315

    D Lotu s Servic e Note s Sectio n JH Outer column assembly, w 80 ± 1 mm Inner column • lower end 58 ±1 mm ran 3 . Inne r Colum n Uppe r Wit h th e steerin g whee l removed , measur e th e lengt h o f th e expose d par t o f th e uppe r colum n a s shown : IhSga l 4 . 'Brea k out ' Insert s Remov e th e colum n shroud s an d th e colum[...]

  • Página 316

    D Lotu s Servic e Note s Sectio n JH 4 . 6 . 7 . 8 . 9 . th e retainin g bar b locate d betwee n th e whit e an d yello w cables . Withdra w th e connector . I f necessary , remov e th e steerin g lock/ignitio n ke y barrel : Tur n th e ke y t o positio n 'I' , depres s th e sprin g pi n accessibl e vi a a hol e i n th e colum n switc h c[...]

  • Página 317

    T o remov e th e intermediat e colum n assembly , th e uppe r colum n mus t firs t b e remove d (se e sub-sectio n HE.3) , afte r whic h th e rac k pinio n shaf t pinc h bol t ma y b e remove d an d th e colum n assembl y withdrawn . Matc h markin g th e lowe r u/ j t o th e pinio n shaf t wil l ai d steerin g whee l alignmen t o n re-assembly . To[...]

  • Página 318

    D Lotu s Servic e Note s Sectio n JH th e housin g an d trac k rod . Chec k fo r consequen t damag e o r wea r an d replac e th e steerin g gea r assembl y i f necessary . Fi t th e ne w gaite r int o position , an d secur e wit h ne w retainin g clips . HE. 6 - RAC K & PINIO N ASSEMBL Y REMOVAL/REPLACEMEN T Th e rac k an d pinio n assembl y i [...]

  • Página 319

    D Lotu s Servic e Note s Sectio n JH 5 . O n re-assembly , fee d th e rac k assembl y int o th e chassi s crossmembe r an d engag e th e pinio n shaf t int o th e lowe r u/ j wit h th e matc h mark s aligned . I f a ne w assembl y i s bein g fitted , follo w th e 'Steerin g Whee l Alignment 1 procedur e i n sub-sectio n HE.2 . 6 . Ne w fixin g[...]

  • Página 320

    D Lotu s Servic e Note s Sectio n J H BRAK E SYSTE M & PEDA L BO X SECTIO N J H - M11 1 Genera l Descriptio n Brak e Flui d Chec k & Chang e Fron t Brak e Pa d Replacemen t Rea r Brak e Pa d Replacemen t Parkin g Brak e Mechanis m Brak e Disc s Maste r Cylinde r Peda l Bo x Calipe r Overhau l Sub-Sectio n Paq e JH. 1 3 JH. 2 3 JH. 3 4 JH. 4[...]

  • Página 321

    D Lotu s Servic e Note s Sectio n J H h . 1 U l ( 3 Pag e 2 1998 / 03[...]

  • Página 322

    Lotu s Servic e Note s Sectio n J H JH. 1 -GENERA L DESCRIPTIO N Th e brakin g syste m o f th e Lotu s M11 1 comprise s o f ventilate d disc s al l roun d wit h A P Racin g 2-pisto n fixe d caliper s o n th e fron t an d Bremb o singl e pisto n slidin g caliper s o n th e rear . A tande m maste r cylinder , withou t serv o assistance , operate s th[...]

  • Página 323

    D Lotu s Servic e Note s Sectio n J H D o NO T us e DO T 5 silicon e fluid , o r an y flui d whic h ha s bee n expose d t o th e atmospher e fo r mor e tha n a brie f period , o r an y flui d suspecte d o f bein g wet , dirt y o r contaminated . D o no t overfill . Replac e th e fille r ca p securely . Som e servic e operations , suc h a s replacin[...]

  • Página 324

    Lotu s Servic e Note s Sectio n J H 2 . Befor e replacin g th e pads , inspec t th e calipe r fo r an y sign s o f flui d leakag e fro m a pisto n sea l o r joint , an d replac e th e calipe r i f an y suc h sign s ar e evident . Clea n th e pa d reces s i n th e calipe r takin g suitabl e precau - tion s t o protec t fro m dus t inhalation . 3 . I[...]

  • Página 325

    D Lotu s Servic e Note s Sectio n J H 4 . Befor e refittin g th e pads , inspec t th e pisto n boo t fo r splits , crack s o r othe r damage , an d fo r an y sign s o f flui d leakag e o r wetness . I f an y suc h sign s ar e apparent , th e complet e calipe r shoul d b e replace d a s Bremb o d o no t recommen d tha t thi s calipe r b e dismantled[...]

  • Página 326

    D Lotu s Servic e Note s Sectio n J H apart , an d i n s o doing , appl y a n axia l forc e t o th e pisto n vi a a screwthrea d an d nut . Th e nu t i s restraine d i n th e pisto n b y a on e wa y clutc h whic h grip s th e nu t whe n th e parkin g brak e i s applied , bu t allow s i t t o tur n whe n th e mechanis m relaxes , o r whe n th e pist[...]

  • Página 327

    D Lotu s Servic e Note s Sectio n J H Afte r verifyin g thi s dimension , an y slac k i n th e rea r cabl e ma y b e adjuste d ou t a t th e lef t han d oute r cabl e abutment , whic h i s integra l wit h th e pivo t bracke t fo r th e fron t le g o f th e lowe r wishbone . I f fitted , th e diffuser / undertra y mus t b e remove d fo r access . Af[...]

  • Página 328

    D Lotu s Servic e Note s Sectio n J H JH. 6 - BRAK E DISC S Al l fou r whee l brake s utilis e a commo n brak e dis c whic h i s sandwiche d betwee n eac h whee l an d it s hub , bein g centralise d b y th e hu b spigot , an d transmittin g torqu e vi a th e clampin g forc e o f th e roa d whee l studs . N o separat e dis c fixing s ar e used . Th [...]

  • Página 329

    JH. 7 - BRAK E MASTE R CYLINDE R Th e tande m brak e maste r cylinde r i s mounte d i n th e fron t compartmen t an d i s secure d t o th e peda l bo x b y tw o M 8 bolts . T o remov e th e unit , procee d a s follows : 1 . Sypho n flui d fro m th e reservoi r t o reduc e spillage . 2 . Disconnec t th e clutc h maste r cylinde r suppl y hos e fro m[...]

  • Página 330

    D Lotu s Servic e Note s Sectio n J H 5 . Pres s th e sto p sleev e agains t th e rea r pisto n an d releas e th e scre w retainin g th e sleeve . Remov e th e sto p sleeve , screw , sprin g an d sprin g sea t washer . Carefull y remov e th e primar y sea l an d groove d sea l fro m th e rea r piston . 6 . Fro m th e fron t piston , remov e th e pr[...]

  • Página 331

    15 . Thinl y coa t th e tw o reservoi r spigot s an d sealin g grommet s wit h AT E Brak e Cylinde r Past e o r AT E Brak e Assembl y Spra y o r similar , an d inser t th e grommet s int o thei r location s i n th e maste r cylinde r body . Fi t th e reservoi r t o th e maste r cylinde r wit h th e tw o spigot s full y inserte d int o thei r gromme[...]

  • Página 332

    D Lotu s Servic e Note s Sectio n J H JH. 8 - PEDA L BO X Th e extrude d aluminiu m allo y peda l bo x i s secure d t o th e chassi s scuttl e vi a si x horizontall y dispose d M 6 screws , thre e fixin g eac h sid e o f th e bo x t o a vertica l bracket , itsel f bonde d an d rivette d t o th e chassis . A n stee l pivo t shaf t i s clampe d int o[...]

  • Página 333

    D Lotu s Servic e Note s Sectio n J H Th e peda l bo x ma y b e remove d fro m th e ca r complet e wit h pedals , bu t t o avoi d hydrauli c flui d los s an d th e necessit y fo r subsequen t bleeding , th e brak e an d clutc h maste r cylinder s shoul d b e release d fro m th e peda l bo x befor e removal : 1 . Releas e brak e maste r cylinde r fr[...]

  • Página 334

    Lotu s Servic e Note s Sectio n J H 8 . O n re-assembly , not e tha t n o lu - bricant s ar e use d i n conjunctio n wit h plasti c bushes , bu t tha t a spe - cia l Do w Cornin g DC3 3 Mediu m greas e (A111F6016 ) i s use d o n th e brak e an d clutc h peda l trunnions . Tak e car e t o correctl y identif y th e brak e an d clutc h pedals : Th e b[...]

  • Página 335

    JH. 9 - CALIPE R OVERHAU L Th e fron t brak e caliper s ar e manufacture d b y A.P . Racing , an d ar e t o b e dismantle d o r overhaule d onl y b y thei r factor y a t Wheele r Road , Seve n Star s Industria l Estate , Coventry , CV 3 4LB . Th e Bremb o rea r brak e caliper s ma y hav e th e slidin g pin s overhaule d a s detaile d below , bu t a[...]

  • Página 336

    D Lotu s Servic e Note s Sectio n JH ENGIN E COOLIN G SECTIO N K F - M11 1 ELIS E Genera l Descriptio n Maintenanc e Drain/Refil l Procedur e Radiato r & Coolin g Fa n Radiato r Fa n Contro l Radiato r Fee d & Retur n Pipe s Wate r Pum p & Thermosta t Sub-Sectio n Pag e KF. 1 3 KF. 2 KF. 3 KF. 4 KF. 5 KF. 6 3 4 6 8 8 Se e Sectio n E E P[...]

  • Página 337

    D Lotu s Servic e Note s Sectio n JH Thermostat Closed Coolant header tank Heater return pipe Heater matrix Heater feed pipe Engine outlet spout Cylinder head air bleed Radiator by-pass circuit Thermostat housing Heater return water rail fk59 l Thermostat Open Radiator- Radiator outlet hose Radiator return pipe Radiator inlet hose Radiator feed pip[...]

  • Página 338

    D Lotu s Servic e Note s Sectio n JH KF. 1 - GENERA L DESCRIPTIO N Th e engin e coolin g syste m comprise s a n engin e drive n wate r pump , a fron t mounte d radiato r wit h elec - tri c coolin g fan , an d associate d pipewor k an d controls . Th e centrifuga l wate r pum p i s mounte d o n th e fron t fac e o f th e cylinde r block , an d i s d[...]

  • Página 339

    D Lotu s Servic e Note s Sectio n JH WARNING : D o NO T remov e th e ca p fro m th e engin e coolin g heade r tan k whe n th e engin e i s warm , a s seriou s scaldin g coul d resul t fro m boilin g wate r and/o r steam . Whe n full y cold , th e leve l o f coolan t shoul d b e u p t o th e 'cold ' mar k moulde d o n th e heade r tank . I[...]

  • Página 340

    D Lotu s Servic e Note s Sectio n JH 1 2 . 3 . Disconnect RH hose at this point [H I T o refil l th e system : Refi t th e hoses , an d fil l wit h th e recommende d coolan t mi x vi a th e heade r tank . Remov e th e blee d scre w i n th e retur n wate r rai l a t th e lef t han d sid e o f th e engine , takin g car e no t t o misplac e th e seali[...]

  • Página 341

    4 . Releas e th e fron t en d o f th e L H fron t wheelarc h liner , t o provid e acces s t o th e radiato r outle t hos e blee d screw . Pressuris e th e syste m t o 3 5 kP a ( 5 lbf/in 2 ) an d ope n th e radiato r hos e blee d scre w unti l a stead y strea m o f coolan t flows . Tighte n th e blee d screw . 5 . Remov e th e pressur e tes t equip[...]

  • Página 342

    D Lotu s Servic e Note s Sectio n JH Water shield Radiator inlet hose Radiator mounting panel Radiator fixing screw Crash structure Radiator Radiator outlet hose 6 . Releas e th e fa n moto r fro m th e radiato r b y removin g th e fou r nut s securin g th e fa n shrou d t o th e mount - in g bracket s rivette d t o th e radiato r frame . Withdra w[...]

  • Página 343

    KF. 5 - RADIATO R FA N CONTRO L Th e engin e managemen t EC M require s a coolan t temperatur e inpu t signa l i n orde r t o increas e fue l deliver y an d maintai n driveabilit y durin g th e col d runnin g an d warm-u p phase . Th e Engin e Coolan t Tempera - tur e (ECT ) senso r supplie s thi s signal , whic h i s als o use d b y th e EC M t o [...]

  • Página 344

    Water rail supporting foam blocks Grommet in chassis front closing panel S D O S I V Water pipe Access into chassis rail ran 1 . Drai n th e coolan t an d remov e th e fron t clamshel l (se e sub-sectio n BN.4) . 2 . WARNING : Th e machine d edge s o f th e chassi s extrusion s an d th e end s o f th e driv e fastener s ca n presen t shar p edge s [...]

  • Página 345

    D Lotu s Servic e Note s Sectio n JH FUE L SYSTE M SECTIO N L H - M11 1 ELIS E Sub-Sectio n Pag e Genera l Descriptio n LH. 1 3 Fue l Fillin g LH. 2 3 Precaution s LH. 3 4 Fue l Filte r LH. 4 4 Fue l Tan k LH. 5 5 Fue l Pump/Sender Assembl y LH. 6 8 Charcoa l Caniste r LH. 7 1 0 Pag e 345 1998 / 03[...]

  • Página 346

    Lotu s Servic e Note s Sectio n L H 3 O £ < D C U l Z LL I < 5 S LL I H ( 0 > - U J L L I Pag e 2[...]

  • Página 347

    D Lotu s Servic e Note s Sectio n JH LH. 1 - GENERA L DESCRIPTIO N Th e 36. 4 litr e (8. 0 imp.gall ) fabricate d stee l fue l tan k i s mounte d withi n th e chassi s crossmembe r be - twee n th e passenge r compartmen t an d engin e bay , wit h th e fue l fille r nec k connectin g t o th e righ t han d to p o f th e tank , an d th e fue l pump/fu[...]

  • Página 348

    D Lotu s Servic e Note s Sectio n JH Filling Procedure: Inser t th e pum p nozzl e full y int o th e neck , an d fil l unti l th e firs t tim e th e auto-shu t of f mecha - nis m i s triggered . D o no t attemp t t o 'brim ' th e tan k t o th e to p o f th e fille r neck , a s expansio n o f th e fue l du e t o temperatur e chang e (espec[...]

  • Página 349

    D Lotu s Servic e Note s Sectio n JH betwee n th e filte r outle t pip e an d th e engin e fee d hos e b y pressin g th e releas e co)ar toward s th e connec - tor , an d slidin g of f th e pip e end . 3 . Pres s bac k th e retainin g clip , an d withdra w th e filte r fro m it s carrier . I f necessary , remov e th e outle t pip e fro m th e filt[...]

  • Página 350

    Releas e th e fee d an d retur n pipe s fro m th e fue l pum p b y squeezin g togethe r th e releas e tab s o n th e pus h fi t connectors , an d withdrawin g fro m th e spigots . Unplu g th e electrica l connecto r fro m th e pum p assembly . I f necessary , sypho n fue l fro m th e tan k t o reduc e th e weigh t befor e removal . Remov e th e R H[...]

  • Página 351

    D Lotu s Servic e Note s Sectio n JH 4 . I f fitted , remov e th e engin e ba y undertray/diffuser . 5 . Disconnec t contro l cables : Releas e th e tw o gearchang e cable s fro m th e transmissio n lever s an d abutmen t bracket . Releas e th e parkin g brak e cabl e fro m th e horsesho e compensato r an d abutmen t brackets . Releas e th e thrott[...]

  • Página 352

    D Lotu s Servic e Note s Sectio n JH Suppor t th e tan k befor e removin g th e fou r bolt s securin g th e fixin g bracket s a t th e bas e o f th e tan k t o th e chassis , an d carefull y lowe r an d remov e th e tank . I Captive fixing Tank rear fixing > Captive fixing Tank front fixing USS l 8 . Refi t th e tan k i n revers e orde r t o rem[...]

  • Página 353

    D Lotu s Servic e Note s Sectio n JH engine , fro m whic h i t return s t o th e inle t connectio n o n th e to p plat e an d spill s int o th e caniste r t o supplemen t th e primar y pum p outpu t an d kee p th e caniste r full y filled . A n umbrell a valv e i n th e botto m o f th e caniste r allow s fuel t o flo w int o th e caniste r wheneve [...]

  • Página 354

    D Lotu s Servic e Note s Sectio n JH Clamp ring Threaded spacer ring •O' ring Pump assembly end plate Fuel level sender float - Fuel pump Sealing '0' ring Fuel tank 4 . m a Fo r acces s t o th e pump , depres s th e thre e retainin g barbs , an d withdra w th e reservoi r caniste r fro m th e pum p assembly . Unplu g th e pum p ele[...]

  • Página 355

    D Lotu s Servic e Note s Sectio n JH a por t i n th e throttl e body , suc h tha t fres h ai r i s draw n throug h th e caniste r t o purg e th e charcoa l o f it s adsorbe d fuel , wit h th e resultan t ga s the n consume d b y th e engin e i n th e norma l combustio n process . Charcoa l Caniste r Thi s i s mounte d a t th e lef t han d fron t co[...]

  • Página 356

    D Lotu s Servic e Note s Sectio n JH Th e to p sid e o f th e charcoa l be d i s connecte d vi a a por t i n th e to p o f th e canister , t o atmosphere . A purgin g port , controlle d b y a solenoi d valv e o n th e to p o f th e canister , connect s th e tan k ven t an d undersid e o f th e charcoa l be d wit h a por t o n th e throttl e bod y s[...]

  • Página 357

    D Lotu s Servic e Note s Sectio n JH ELECTRIC S SECTIO N M N - M11 1 ELIS E Sub-Sectio n Paq s Vehicl e Securit y Alar m (Standar d Luca s & Cobr a 6019H F option ) MN. 1 2 'Lotu s Check ' Scanne r Too l MN. 2 7 Switche s & Instrument s - Driver' s Informatio n MN. 3 9 Componen t Locatio n & Fus e Rating s (prio r Oct . &[...]

  • Página 358

    MN. 1 - VEHICL E SECURIT Y ALAR M (Standar d Luca s & Cobr a 6019H F option ) Prio r t o Octobe r '97 , Elis e model s ma y b e equippe d wit h on e o f tw o level s o f alar m system . Th e bas e syste m use s a Luca s 5A S modul e whic h i s electronicall y matche d t o th e engin e managemen t EC M t o provid e a passiv e immobilise r f[...]

  • Página 359

    1 . Spli t th e transmitte r cas e usin g a finge r nai l o r blad e i n th e cas e jointline . 2 . Slid e th e batter y ou t o f it s keeper , an d inser t th e new , takin g car e t o matc h th e polarit y marking . 3 . Sna p th e cas e halve s together . Th e 5A S modul e i s mounte d behin d th e fasci a o n th e steerin g colum n uppe r bracke[...]

  • Página 360

    triggerin g signa l i s stil l presen t (e.g . i f a doo r i s lef t open) , th e alar m wil l repea t afte r a shor t delay , an d continu e i n thi s sequenc e fo r a tota l o f te n cycles . To Disarm the Alarm: Pres s onc e th e embosse d re d butto n o n th e transmitte r key . Thi s comman d wil l b e acknowledge d by : a singl e flas h o f t[...]

  • Página 361

    D Lotu s Servic e Note s Sectio n JH Althoug h th e alar m syste m draw s onl y a tin y current , i f th e vehicl e i s t o b e parke d fo r a n extende d perio d o f tim e (ove r thre e week s i n summer , o r tw o week s i n winter) , i t i s recommende d t o reduc e curren t drai n t o a minimu m b y switchin g of f th e alar m syste m wit h th [...]

  • Página 362

    D Lotu s Servic e Note s Sectio n JH Buzzer sounds? (NO). e) . Se t u p i s okay . f) . I f adjustmen t i s required , remov e th e tw o circula r plasti c piece s holdin g th e uni t together , an d separat e th e tw o halve s o f th e case . Tur n th e adjuste r scre w (to p lef t han d corner ) a s required , an d repea t th e test . Note : I f [...]

  • Página 363

    D Lotu s Servic e Note s Sectio n JH bracket , an d ma y b e accesse d afte r remova l o f th e colum n shroud s an d instrumen t pac k (se e sub-sectio n BN.12) . Front lid microswitch Alarm system keys Immobiliser touch key Rear lid microswitch Siren Override switch Microwave unit immobiliser module MN. 2 - 'LOTU S CHECK ' SCANNE R TOO [...]

  • Página 364

    D Lotu s Servic e Note s Sectio n JH Powe r Harness ; Adapto r Harness ; MEM S 1. 9 Programm e Card ; 5A S Securit y Programm e Card ; Securit y Modul e ('Dongle') ; Instructio n Booklet . Power harness T o Connec t 'Lotu s Check ' T o connec t th e equipment , procee d a s follows : i) . Ope n th e fron t an d rea r compartmen [...]

  • Página 365

    D Lotu s Servic e Note s Sectio n JH Th e use r passwor d ma y b e change d o r recharge d b y th e superviso r a t an y time . Eac h tim e a securit y opera - tio n i s performed , a charg e i s debite d agains t tha t superviso r password , wit h th e remainin g numbe r o f charge s advise d vi a th e scanne r display . Whe n thi s numbe r reduce[...]

  • Página 366

    D Lotu s Servic e Note s Sectio n JH Passive Immobilisation: I f th e ignitio n ha s bee n switche d of f fo r longe r tha n 3 0 seconds , i t i s possibl e tha t th e passiv e immobilisatio n securit y featur e ma y operat e (dependen t o n typ e o f alar m fitted ) an d disabl e th e ignitio n an d starte r circuits ; pres s th e appropriat e tra[...]

  • Página 367

    D Lotu s Servic e Note s Sectio n JH fastened . Bot h drive r an d passenge r shoul d alway s wea r th e sea t belts , n o matte r ho w shor t th e journey . Mai n Bea m Tel l Tal e Thi s lam p glow s blu e wheneve r th e headlam p mai n beam s ar e operating . Alar m Tel l Tal e Th e re d vehicl e securit y alar m tel l tal e indicate s th e statu[...]

  • Página 368

    D Lotu s Servic e Note s Sectio n JH th e coolin g fa n switchin g o n a t approximatel y 104°C . The display will flash at temperatures over 100°C in orde r t o promp t close r monitorin g o f hig h temperatures , bu t a s th e pressurise d coolin g syste m ha s a boilin g poin t o f ove r 120°C , onl y i f th e temperatur e approache s thi s l[...]

  • Página 369

    D Lotu s Servic e Note s Sectio n JH Hazar d Warnin g Lamp s Switc h A re d tel l tal e i n th e switc h butto n i s bac k li t whe n th e sidelamp s ar e switche d o n i n orde r t o hel p locat e th e switch . Th e switc h i s operativ e a t al l times , an d whe n presse d flashe s al l th e tur n indicato r lamps , an d th e switc h tel l tale [...]

  • Página 370

    D Lotu s Servic e Note s Sectio n JH Not e tha t o n car s equippe d wit h th e optiona l drivin g lamp s mounte d i n th e radiato r ai r intake , th e bonne t mounte d headlam p mai n beam s ar e supplemente d b y th e tw o drivin g lam p beams . Headlamp Flasher: Th e headlam p flashe r i s operativ e a t al l times . I f th e leve r i s pulle d[...]

  • Página 371

    D Lotu s Servic e Note s Sectio n JH MN. 4 - COMPONEN T LOCATIO N & FUS E RATING S Mai n Fusebo x 'A ' Th e mai n fusebo x i s locate d i n th e fron t service s compartment , o n th e passenge r side , an d i s protecte d b y a clea r plasti c cover . Twelv e 'Litte r typ e fuse s ar e fitte d alongsid e fou r rela y modules . T[...]

  • Página 372

    D Lotu s Servic e Note s Sectio n JH Th e wash/wip e module , an d hazar d flashe r rela y ar e mounte d behin d th e passenge r sid e chassi s scuttl e beam . Fo r th e locatio n o f th e vehicl e alar m syste m components , se e sub-sectio n MN.1 . Engin e managemen t component s ar e detaile d i n Sectio n EMN . Fuse colours: 2 A - Black ; 3 A -[...]

  • Página 373

    D Lotu s Servic e Note s Sectio n JH MN. 5 - AUDI O EQUIPMEN T Al l car s ar e provide d wit h a radi o IS O connecto r an d aeria l lead , whic h o n car s no t buil t wit h a n audi o set , ar e tie d bac k t o th e fasci a harness . A n IS O siz e hol e i s provide d i n th e dash , requirin g onl y tha t th e moulde d plasti c finishe r i s rep[...]

  • Página 374

    D Lotu s Servic e Note s Sectio n JH MN. 6 - BATTERY . BATTER Y CABLE S & EARTHIN G POINT S Batter y WARNING : POISON/DANGE R - CAUSE S SEVER E BURN S - KEE P OU T O F REAC H O F CHILDREN . Contain s sulphuri c aci d - avoi d contac t wit h skin , eye s o r clothing . Antidote : Externa l - flus h wit h water ; Interna l - drin k larg e quantit[...]

  • Página 375

    Lotu s Servic e Note s Sectio n M N sire n housin g i n th e to p o f th e passsenge r footwell , an d tur n counterclockwise . ii ) Wai t fo r a t leas t te n second s afte r switchin g of f th e ignitio n t o allo w th e engin e managemen t syste m t o adjus t th e settin g o f som e component s read y fo r re-starting . iii ) Ensur e tha t al l [...]

  • Página 376

    Eart h Point s Ther e ar e onl y tw o eart h connection s t o th e chassis , on e a t th e fron t fo r th e batter y eart h lead , an d on e a t th e lef t han d sid e o f th e engin e ba y fo r th e engin e eart h braid , an d rea r harnes s earthin g requirements . A t bot h points , th e anodise d surfac e treatmen t mus t b e remove d fro m th [...]

  • Página 377

    • Th e engin e managemen t eart h cable s ar e gathere d a t a insulate d binding pos t a t th e fron t o f th e EC M mountin g panel , wit h a n eart h cabl e connectin g thi s pos t t o th e chassi s eart h point . Thi s arrangemen t i s use d t o reduc e th e ris k o f eart h path s bein g create d throug h th e EC M casing . MN. 7 - WIPE R ME[...]

  • Página 378

    Lotu s Servic e Note s Sectio n M N MN- 8 - FITMEN T O F DRIVIN G LAMP S Th e optiona l drivin g lamp s mounte d i n th e ai r intak e apertur e provid e additiona l lightin g o n mai n beam , operatin g i n conjunctio n wit h th e mai n headlamps . Al l car s ar e buil t wit h a wirin g harnes s whic h accommo - date s th e drivin g lamps , whic h[...]

  • Página 379

    Lotu s Servic e Note s Sectio n M N 1 . Remov e th e fron t clamshel l an d remov e th e ai r intak e grill e fro m th e cras h structur e togethe r wit h tw o o f th e 'Scrivet ' threade d fixings . Transfe r thes e t o th e to p o f th e clamshel l intak e apertur e (pre-drille d holes) . 2 . Fi t th e M 8 Pulsert s fo r th e mountin g [...]

  • Página 380

    Lotu s Servic e Note s Sectio n M N Main harness along dash (LHD shown) Push switches Instrument pack Lucas 5AS module Hazard & wash/wipe module Door switch connector Column switch connectors FnTB a Cobra Alarm Harness (RHD shown) Immobilier touch key socket Lucas 5AS module connectors J0 3 JO ? M 27 - Connector to siren unit Alarm controller M[...]

  • Página 381

    Lotu s Servic e Note s Sectio n M N Main harness into engine bay Engine management earth point Harness out of fuel tank bay Engine earth Chassis lead earth point Wheel speed sensor Main harness at ECM panel Engine management ECM Rear harness connector DLC Engine harness connectors Relay module Inertia switch Imft^ l Pag e 2 5[...]

  • Página 382

    Lotu s Servic e Note s Sectio n M N Rear clamshell harness Connector to main harness High mounted stop lamp Licence plate lamp Front clamshell harness I m19 3 Connector to main harness Im197 l Pag e 2 6[...]

  • Página 383

    Lotu s Servic e Note s Sectio n M N Centre tunnel harness routing Cigarette lighter terminals Rubber edging Foam pad Protective channel Into fuel tank bay Note use of 'P' clips, tie wraps and edge protection as shown Pag e 2 7[...]

  • Página 384

    MN.1 0 - INTRODUCTIO N O F UPRATE D STARTE R MOTO R I n Februar y '97 , th e starte r moto r wa s uprate d fro m 1. 0 k W t o 1. 4 kW , wit h attenden t benefit s t o ho t star t performance . I n orde r t o optimis e th e vehicl e wirin g harnes s i n respec t t o voltag e dro p characteristics , th e powe r suppl y t o th e engin e managemen[...]

  • Página 385

    Lotu s Servic e Note s Sectio n M N MN.1 1 - CIRCUI T DIAGRAM S - Prio r t o Oct . '9 7 Circuit Sheet Start , Alternato r & Ignitio n 1 Fue l Pum p & Coolin g Fa n 2 Engin e Managemen t Syste m 3 Alar m & Immobilise r (Lucas) , Interio r Lam p & Hor n 4 Alar m & Immobilise r (Cobra) , Interio r Lam p 5 Sto p & Revers e [...]

  • Página 386

    Lotu s Servic e Note s Sectio n M N Pag e 3 0[...]

  • Página 387

    Lotu s Servic e Note s Sectio n M N START , ALTERNATO R & IGNITIO N SHEE T I[...]

  • Página 388

    'o [V: 1 Lotu s Servic e Note s Sectio n M N FUE L PUM P & COOLIN G FA N SHEE T 2[...]

  • Página 389

    'o [V: 1 Lotu s Servic e Note s Sectio n M N ENGIN E MANAGEMEN T SYSTE I FUSEBO X BATTER Y { > -> IGNITIO N [STAR T DROP-OUT I IO N I T I O N IUNFUSED I IGNITIO N I FUSED ) < n IGNITIO N COI L i o MSrnuuEN r PAC K ITACHOMETER ) SE E SI£E T 10 ) = U J THROTTL E " J PO T S'EPPE R MOTO R EH C A :H C <x > m - loi n j m j [...]

  • Página 390

    'o [V: 1 Lotu s Servic e Note s Sectio n M N ALAR M & IMMOBILISE R (LUCAS ! FUSEBO X TUSEBO X BATTER Y IGNITIO N (STAR T DROP-OUT ) FUS E BO X IGNITIO N (UNFUSE0 1 IGNITIO N IFUSED I SHEE T 4[...]

  • Página 391

    'o [V: 1 Lotu s Servic e Note s Sectio n M N ALAR M & IMMOBILISE R (COBRA ) SHEE T 5[...]

  • Página 392

    'o [V: 1 Lotu s Servic e Note s Sectio n M N STO P & REVERS E LAMP S SHEE T 6[...]

  • Página 393

    'o [V: 1 Lotu s Servic e Note s Sectio n M N DIRECTIO N INDICATOR S & HAZAR D LAMP S FUS E BO * BA T TE H Y IGNITIO N (STAR T DROP-OUT ) FUSEBO X 1GNI T 1 O N (UNFUSEO I IGNITIO N IFUSEO L T > H > HAZAR D SWITC H 12 V S1CELAUP 5 E E SHEE T 9 HAZAR D HASHER . SHEE T 7[...]

  • Página 394

    'o [V: 1 Lotu s Servic e Note s Sectio n M N HEADLAMP S SHEE T 8[...]

  • Página 395

    'o [V: 1 Lotu s Servic e Note s Sectio n M N SIDELAMP S D FO G LAM P SHEE T 9[...]

  • Página 396

    'o [V: 1 Lotu s Servic e Note s Sectio n M N INSTRUMENT S IGNITIO N (STAR T DROP-OUT ) { > IGNITIO N (UNFUSED ) IGNI T IO N (FUSED ) INSTRUMEN T PAC K SEA T BEL T WARNIN G BUZZE R 5EA T 1 PAR K BRAK E CA T BEL T BRAK E FL U I D O'HEA T LE D LE O LE D LE D S .J - r i OI L WATE R FUE L ,=n-s s TEM P -EVE L 1 LE D LC D LC D f ' r ( [...]

  • Página 397

    ' o [V : 1 Lotu s Servic e Note s Sectio n M N WINDSCREE N WIPER S BATTER Y SHEE T 397[...]

  • Página 398

    'o [V: 1 Lotu s Servic e Note s Sectio n M N INTERIO R FA N BATTER Y SHEE T 1 2[...]

  • Página 399

    'o [V: 1 Lotu s Servic e Note s Sectio n M N RADI O D CIGA R L IGHTE R SHEE T 1 3[...]

  • Página 400

    'o [V: 1 Lotu s Servic e Note s Sectio n M N POWE R & GROUN D STRUCTUR E SHEE T 1 4[...]

  • Página 401

    Lotu s Servic e Note s Sectio n M N INTER-HARNES S CONNECTOR S CONNECTO R O N MAI N HARNES S CONNECTO R O N MATIN G HARNES S ••co m un m mm m ft ERON T & REA R HARNES S CONNECTOR S (FH C & RHC ) m i 2 i i 3 i m in m i 7 i i 8 i T O a s a ® EHE H QUEI l ENGIN E HARNES S CONNECTO R I (EH' C n n •dMJSli ] HEni ® EDirriUsilBI i BLU[...]

  • Página 402

    Lotu s Servic e Note s Sectio n M N FUSE S FUSEBO X A • •••••••••• • • •••••••••• • 1 2 I I 1 0 9 o o 8 7 6 5 a Q O B 4 3 2 o o NO . RATIN G APPLICATIO N 0 1 3 A REA R FO G LA W 0 2 Z A ALAR M 0 3 1 5 A INTERIO R FA N 0 4 1 5 A WIPE R MOTO R 0 5 3 A REVERS E LAM 2 0 G 7.5 A DIREC T I O N INDICATOR S 0[...]

  • Página 403

    Lotu s Servic e Note s Sectio n M N MN.1 2 - COBR A 642 2 VEHICL E SECURIT Y ALAR M (U.K . option ^ Th e optiona l upgrade d vehicl e alar m syste m o n U.K . marke t car s wa s update d fro m a Cobr a 6019H F t o a Cobr a 642 2 base d syste m fro m th e followin g chang e point : VIN ; W 194 7 (October'97) ; plu s W 193 8 Th e 642 2 syste m m[...]

  • Página 404

    Lotu s Servic e Note s Sectio n M N Not e tha t i f th e syste m i s arme d whe n a door , engin e li d o r fron t bonne t i s no t full y closed , a buzze r wil l soun d continuousl y unti l th e openin g i s secured . I f stil l ope n afte r 4 0 seconds , th e sire n wil l sound . Afte r armin g th e system , a perio d o f a t leas t 4 0 second s[...]

  • Página 405

    Lotu s Servic e Note s Sectio n M N Emergenc y Disarmin g I n th e even t o f los t o r faile d transmitte r keys , a n electroni c touc h ke y ma y b e use d t o mobilis e th e engine : Ente r th e vehicl e (causin g th e alar m t o b e triggere d i f i t i s armed) , an d wit h th e ignitio n OFF, inser t th e touc h ke y int o th e receptacl e o[...]

  • Página 406

    Alar m Troubl e Shootin g Symptom: Vehicl e wa s lef t fo r a fe w minute s withou t settin g th e alarm , an d no w th e engin e won' t start . Possible cause: Passiv e immobilisatio n ha s take n effec t (indicate d b y th e tel l tal e flashing) , a s designe d - se e above . Symptom: Th e transmitte r ke y wil l no t ar m o r disar m syste[...]

  • Página 407

    Lotu s Servic e Note s Sectio n M N Locatio n o f Alar m Component s Siren Alarm controller (on early cars may be fitted above passenger footwell) Touch key socket Siren connector Pag e 3 5[...]

  • Página 408

    MN.1 3 - FUSE S & RELAY S (Oct . '9 7 onwards ) A ne w mai n fusebo x an d wirin g harnes s wa s introduce d i n Octobe r 199 7 a t th e followin g changepoint : VIN : W 194 1 onward s plus ; 1920 , 1926 , 1937 , 193 8 less ; 1965,200 2 Th e passenge r sid e o f th e fron t service s compartmen t house s th e mai n fusebo x wit h provisio [...]

  • Página 409

    Lotu s Servic e Note s Sectio n M N MN.1 4 - CIRCUI T DIAGRAM S - Oct . '9 7 onward s Circuit Sheet Start , Alternato r & Ignitio n 1 Fue l Pum p & Coolin g Fa n 2 Engin e Managemen t Syste m 3 Alar m & Immobilise r (Lucas ) 4 Alar m & Immobilise r (Cobr a 6422 ) 5 A Sto p & Revers e Lamp s 6 Directio n Indicator s & Ha[...]

  • Página 410

    Lotu s Servic e Note s Sectio n M N START , ALTERNATO R & IGNITIO N SHEE T I[...]

  • Página 411

    Lotu s Servic e Note s Sectio n M N FUE L PUM P & COOLIN G FA N - O o T > IG N ITIO N ISTAR T OROP-OUT I IGNITIO N HJNFU5E0 ) IG N ITIO N (FUSED * 2 5 = '9 s r r - N i i ] B R [DC*I N G L iN t O R ' OBR A IMUOBI L 1SE R v ; - c • ! r j il l 5ME E r 1 0 8 5 A A 3 0 ICHASSI S (REAR ) -t > SHEE T 2A[...]

  • Página 412

    Lotu s Servic e Note s Sectio n M N ENGIN E MANAGEMEN T SYSTE M SHEE T 3A[...]

  • Página 413

    Lotu s Servic e Note s Sectio n M N ALAniv l Os . iMMUbl L IBTR ? ILU CAS I SHEE T 4A[...]

  • Página 414

    Lotu s Servic e Note s Sectio n M N ; STAR T RELA Y [G N SWITC H $ A I CVEP R ID E K E t ? i ' 6 1-1 5 , Co T 2 > -jcOO E 0 I I ( L _ J 4 , j CU T I j j iMMOBI L ISE R - i = = = < a |3N_ D O N D -1 5 C O V I C a 0 1 II I i, " i c 1 SE E SHEE T 2 Ostu d [CHASSI S IREA R ) SHEE T 5 A[...]

  • Página 415

    Lotu s Servic e Note s Sectio n M N STO P & REVERS E LAMP S IGNITIO N (STAR T DR0P-0UT I FUSEBO X IGNITIO N (UNFUSED 1 IGNITIO N (FUSED ) o o T > T > T O INSTRUMEN T SE E SHEE T 1 0 T O H0P 1 RELA t L ^ SE E SHEE T 4 ' 0 DIAGNOSTI C .CNkECTO U sE E SHEE T 3 ; I i c p H C RH C I TA' N REVERS E L AVP S USE D -U N MA L Ai3 1 A N CA[...]

  • Página 416

    Lotu s Servic e Note s Sectio n M N DIREC T 1Q N INDICATOR S & HAZAR D LAMP S FUSEBO X BATTER r IGNITIO N ISTAR T DROP-OUT ! FUSEBO X IGNITIO N IUNFUSED I IGNITIO N (FUSE0 1 SHEE T 7A[...]

  • Página 417

    Lotu s Servic e Note s Sectio n M N HEADLAMP S SHEE T 8A[...]

  • Página 418

    Lotu s Servic e Note s Sectio n M N SIDELAMP S & FO G LAM P SHEE T 9A[...]

  • Página 419

    Lotu s Servic e Note s Sectio n M N INSTRUMENT S SHEE T 10A[...]

  • Página 420

    Lotu s Servic e Note s Sectio n M N WINDSCREE N WIPER S BATTER r SHEE T 420A ( ([...]

  • Página 421

    Lotu s Servic e Note s Sectio n M N INTERIO R FA N - O H > IGNITIO N (STAR T 0R0P-0UT I IGNITIO N (UNFUSEO I IGNITIO N (FUSED ) FA N SPEE D SWITC H ' W 3 > W ^VvVOVVVo l H : 1 RESiSTO R BLOC K c > SHEE T 12A[...]

  • Página 422

    Lotu s Servic e Note s Sectio n M N RADI O & C IGA R L IGHTE R SHEE T 13A[...]

  • Página 423

    Lotu s Servic e Note s Sectio n M N POWE R & GROUN D STRUCTUR E SHEE T 14A[...]

  • Página 424

    Lotu s Servic e Note s Sectio n M N INTER-HARNES S CONNECTOR S CONNECTO R O N MAI N HARNES S CONNECTO R O N MATIN G HARNES S ••GOEE ) ex : m mm m FRON T d REA R HARNES S CONNECTOR S (FH C d RH C I mm a m c m mmm . rr HBIII0 0 0 0 aii ] E H E D 011 ® - i ENGIN E HARNES S CONNECTO R ! IEH C ! n o [CdHBd ] EHQHUlillEI ] BLU E ENGIN E HARNES S CON[...]

  • Página 425

    Lotu s Servic e Note s Sectio n M N FUSEBO X A 2 2 2 1 2 0 1 9 1 8 1 7 I S 1 5 1 4 1 3 1 2 • ••••••••• • • ••••••••• • 1 1 1 0 • ••••••••• • • ••••••••• • NO . RATIN G APP L ICA T IO N 0 1 3 A REA R FO G LAM 3 0 2 2 A ALAR M 0 3 1 5 A INFERIO R PA N 0 4 1 5 A WI[...]

  • Página 426

    Lotu s Servic e Note s Sectio n M N HO T SOA K PUM P A/ C CAR S - o 1G N I T IO N ISTAR T QRQP-QUT L IGNITIO N IUNFUSEO I IGNITIO N IFUS£D I HO T SOA K S#ITC H SHEE T 17A[...]

  • Página 427

    Lotu s Servic e Note s Sectio n M N COOLIN G FA N RELA Y 2 A/ C CAR S H > { > H > H > IGNITIO N fSTAR T DROP-OUT l IGNITIO N (UNPUSED ) IGNITIO N (FUSED ! c C 1 CHASSI S iflEAH i _ L SHEE T 18A[...]

  • Página 428

    Lotu s Servic e Note s Sectio n M N INTERIO R FA N A/ C CAR S SHEE T 19A[...]

  • Página 429

    Lotu s Servic e Note s Sectio n M N SOLENOI D VALV E CONTRO L A/ C CAR S -t > -> IGNITIO N ISTAR T OROP-OUT ! IG N [ T IO N (UNFUSED ) SPLIC E B SP L IC E B IG N [T]O N IFUSED ) SOLENOI D VALV E CONTRO L SWITC H FOOTWEL L FLA P SOLENOI D SCREE N FLA P SOLENOI D RECIRCULATIO N SOLENOI u -| > SHEE T 20A[...]

  • Página 430

    Lotu s Servic e Note s Sectio n M N A C REQUES T & CONTRO L NO N HEATE R VERSIO N BATTER Y IGNITIO N (STAR T QRQP-QUT L SHEE T 22A[...]

  • Página 431

    Lotu s Servic e Note s Sectio n O G MAINTENANC E & LUBRICATIO N SECTIO N O G - M11 1 ELIS E Pag e Recommende d Lubricant s 2 Maintenanc e Schedul e 4 Pre-Deliver y Inspectio n 7 199 8 /O S Pag e 1[...]

  • Página 432

    Lotu s Servic e Note s Sectio n O G RECOMMENDE D LUBRICANT S Engin e I n orde r t o ensur e th e longevit y an d reliabilit y o f th e vehicle , i t i s mos t importan t tha t onl y th e specifie d lubricant s ar e used . I t i s a n entirel y fals e econom y t o tr y t o sav e mone y b y usin g lowe r qualit y oils , whic h ma y brea k dow n befor[...]

  • Página 433

    Lotu s Servic e Note s Sectio n O G Brak e & Clutc h Syste m Typ e Specificatio n Capacit y - brak e - clutc h Flui d chang e interva l Engin e Coolan t Additiv e Typ e Concentratio n Syste m capacit y Coolan t chang e interva l Non-minera l (non-petroleum ) hydrauli c flui d DO T 4 1. 5 litr e 0. 5 litr e 1 2 month s Unipar t Supe r Plu s Anti[...]

  • Página 434

    MAINTENANC E SCHEDUL E - M11 1 ELIS E LSL348 B Date : Owner' s Name : Vehicle : Vehicl e Registratio n No. : V.I.N. : Recorde d Mileage : Month s Sinc e Las t Service : Jo b No. : EXPLANATOR Y NOTES : Require d Maintenanc e I n orde r t o maintai n warrant y validatio n an d hel p ensur e prope r safety , emission s performanc e an d dependabi[...]

  • Página 435

    Lotu s Servic e Note s Sectio n O G O p No . OPERATIO N DESCRIPTIO N SERVIC E TYP E O p No . OPERATIO N DESCRIPTIO N Afte r Sale s A B c Othe r Interval s 1 Fi t protectiv e cover s t o seats , footwells, steerin g whee l & rea r bod y X X X X Lubrication 2 Rene w engin e oi l & filter * X X X X 3 Inspec t engin e & transmissio n fo r o[...]

  • Página 436

    Lotu s Servic e Note s Sectio n O G O p No . OPERATIO N DESCRIPTIO N SERVIC E TYP E O p No . OPERATIO N DESCRIPTIO N Afte r Sale s A B c Othe r Interval s Wheel s & Tyre s 2 7 Inspec t tyr e conditio n & se t pressure s X XX X Electrical 2 8 Chec k batter y terminal s fo r securit y & conditio n X X X 2 9 Inspec t operatio n o f al l li[...]

  • Página 437

    Lotu s Servic e Note s Sectio n O G Model : PRE-DELIVER Y INSPECTIO N - ESPRI T V 8 & ELIS E Colour : V.I.N. : SC C LSL34 5 OPERATIO N Espri t Elis e Fi t protectiv e cover s t o seats , footwell s & steerin g whee l X X Engin e Ba y Chec k engin e & transmissio n oi l level s X X Chec k securit y o f engin e oi l filte r X X Chec k coo[...]

  • Página 438

    Lotu s Servic e Note s Sectio n O G Espri t Fron t Spoile r Li p Th e tw o par t fron t spoile r li p i s supplie d i n th e luggag e compartmen t complet e wit h fixings . Th e li p i s fitte d betwee n th e oi l coole r undershield s an d th e spoiler : Remov e th e 4 fixing s fro m eac h undershiel d an d inser t th e spoile r lip . Refi t th e [...]

  • Página 439

    Lotu s Servic e Note s Sectio n XA HEATIN G & VENTILATIO N SECTIO N P F - M11 1 ELIS E Genera l Descriptio n Contro l Cable s Heate r Matri x & Blowe r Fa n Uni t Sub-Sectio n Pag e PF. 1 2 PF. 2 4 PF. 3 7 Pag e 15[...]

  • Página 440

    Lotu s Servic e Note s Sectio n XA PF. 1 - GENERA L DESCRIPTIO N Th e principa l component s o f th e heater/ventilatio n syste m compris e a heate r matri x unit , incorporatin g a n ai r blen d flap , a blowe r fan , a diverte r fla p assembly , an d fou r fasci a outle t vents . Th e syste m provide s heate d o r ambien t ai r t o th e fasci a v[...]

  • Página 441

    Lotu s Servic e Note s Sectio n XA Heater Circuit Heater matrix Heater return pipe Heater feed pipe Cylinder head outlet pipe Thermostat housing Heater return/radiator by-pass rail Distribution flap housing Convoluted ducting Footwell vent adaptor Matrix housing rubber strap Matrix air feed adaptor Heater matrix Air inlet collector Blower fan unit [...]

  • Página 442

    Lotu s Servic e Note s Sectio n XA A cabl e operate d 'ai r blend ' temperatur e contro l flap , operate s betwee n a heate r matri x outle t doorway , an d a matri x by-pas s port , an d control s th e proportio n o f ho t an d col d ai r supplie d t o th e blowe r fa n unit . Th e blowe r fa n i s mounte d alongsid e th e heater , an d [...]

  • Página 443

    Lotu s Servic e Note s Sectio n XA 5 . Tw o identica l slide r contro l leve r assemblie s ar e use d fo r th e hea t an d distributio n functions , eac h bein g secure d t o th e das h wit h tw o countersun k screw s an d nuts , wit h th e scre w head s conceale d b y a graphi c strip . Th e end s o f th e soli d wir e inne r contro l cable s ar e[...]

  • Página 444

    Lotu s Servic e Note s Sectio n XA 7 . Th e distributio n contro l cabl e run s fro m th e uppe r selecto r leve r t o th e botto m o f th e fla p spindl e o n RH D cars , an d t o th e to p o f th e fla p spindl e o n LH D cars : RH D cars : Acces s t o th e distributio n fla p leve r i s availabl e fro m withi n th e passenge r footweli . Wit h t[...]

  • Página 445

    Lotu s Servic e Note s Sectio n XA Equal arcs Ideal adjustment of control cable to attain equal arcs of flap lever travel Flap lever Control cable PF. 3 • HEATE R MATRI X & BLOWE R FA N UNI T Th e heate r matri x i s sandwiche d betwee n tw o plasti c moulding s an d i s clampe d t o th e blowe r fa n uni t b y a rubbe r strap . Th e complet [...]

  • Página 446

    Lotu s Servic e Note s Sectio n XA T o remov e th e matri x o r blowe r fa n unit , th e complet e assembl y shoul d b e remove d fro m th e chassis : 1 . Remov e th e washe r bottle , batter y an d blowe r fa n outle t ducting . 2 . Labe l an d disconnec t th e electrica l lead s t o th e blowe r fan . 3 . Releas e th e sprin g cli p securin g th [...]

  • Página 447

    Lotu s Servic e Note s Sectio n OG AI R CONDITIONING . HEATIN G & VENTILATIO N SECTIO N P H - ELIS E & EXIG E 200 0 M.Y . Sub-Sectio n Paq e Genera l Descriptio n PH. 1 2 Control s Operatio n & Airflo w Distributio n PH. 2 5 Vacuu m Contro l Syste m PH. 3 9 A.C . Clutc h & Coolin g Fa n Contro l PH. 4 1 2 Coolan t Re-circulatio n Pu[...]

  • Página 448

    Lotu s Servic e Note s Sectio n P H Heate r Circui t Heater matrix Water feed pipe along outside of RH chassis sideraii Water return pipe' along outside of LH chassis sideraii Refrigeran t Circui t Water return to engine side of thermostat Coolant re-circulation pump Water valve [p77a l Pag e 2 200 0 / 0 4[...]

  • Página 449

    PH. 1 - GENERA L DESCRIPTIO N Thi s sectio n cover s Elis e an d Exig e model s buil t i n yea r 200 0 fitte d wit h ai r conditioning . Fo r car s wit h a heate r alone , refe r t o sectio n PF . Fo r car s buil t prio r t o 200 0 an d fitte d wit h a.c . alon e (n o heater ) refe r t o sectio n PG . Ai r Conditionin g - Basi c Principle s Th e ai[...]

  • Página 450

    Lotu s Servic e Note s Sectio n P H Condense r Th e aluminiu m condense r i s horizontall y mounte d beneat h th e engin e coolin g radiator , an d i s o f paralle l flo w construction . Th e ho t vapou r receive d b y th e condense r fro m th e compresser , release s hea t t o th e surroundin g ai r vi a th e condense r finning , wit h airflo w bo[...]

  • Página 451

    Lotu s Servic e Note s Sectio n P H PH. 2 - CONTROL S OPERATIO N & AIRFLO W DISTRIBUTIO N Th e interio r climat e control s consis t o f thre e rotar y control s fo r fa n speed , tempera - tur e an d ai r distribution , an d tw o pus h switche s fo r ai r conditionin g an d ai r re-circulation . a.c. switch Temperature Recirculation switch Fan[...]

  • Página 452

    Lotu s Servic e Note s Sectio n P H Temperatur e Th e temperatur e contro l i s a secto r rac k an d pinio n operatin g a contro l cabl e linke d t o th e ai r blen d fla p i n th e heate r housing . Turne d full y counterclockwise , th e fla p i s move d t o direc t al l airflo w t o by-pas s th e heate r matrix . A t thi s position , th e rac k s[...]

  • Página 453

    Lotu s Servic e Note s Sectio n OG Ai r Distributio n Plenu m Th e ai r distributio n plenu m i s mounte d o n th e to p o f th e chassis , sandwiche d betwee n th e scuttl e an d th e windscree n fram e demis t duct . Ai r i s ducte d int o th e plenu m fro m th e blowe r fa n vi a flexibl e trunking , an d flow s fro m th e uni t int o furthe r i[...]

  • Página 454

    Lotu s Servic e Note s Sectio n P H Ai r Distributio n Airflo w Th e distributio n contro l kno b provide s fou r set - ting s a s follows : Face Level: Turne d full y counterclockwise , al l th e airflo w i s directe d t o th e fou r fac e leve l vents , eac h o f whic h ma y b e individuall y adjuste d vi a a volum e con - tro l thumbwhee l an d [...]

  • Página 455

    Lotu s Servic e Note s Sectio n P H PH. 3 - VACUU M CONTRO L SYSTE M Engin e vacuum , tappe d fro m th e intak e plenum , i s use d t o operat e th e screen , footwel i an d re-circ . flaps , an d th e wate r valve . Th e vacuu m suppl y t o eac h o f th e actuator s i s controlle d b y separat e solenoi d valve s mounte d o n a bracke t abov e th [...]

  • Página 456

    Lotu s Servic e Note s Sectio n P H LHP shown Yellow harness tag (water valve) Vacuum reservoir Inlet port to engine Shown with RH rear wheelarch liner removed Outlet port to solenoid valves < D Pag e 1 0 200 0 / 0 4[...]

  • Página 457

    Lotu s Servic e Note s Sectio n P H Distributio n Contro l Detail s Th e distributio n contro l i s a n electrica l selecto r switc h wit h on e inpu t termina l an d usin g 3 outpu t termi - nals . Switc h functionalit y i s a s follows : [ o B FUJ1SOK U Switch terminal C L M H Cable colour Gree n Gree n & Blac k Gree n & Purpl e Gree n &a[...]

  • Página 458

    Lotu s Servic e Note s Sectio n XA PH. 4 - A C . CLUTC H & COOLIN G FA N CONTRO L A.C . Contro l Whe n th e a.c . reques t butto n o n th e fasci a i s pressed , th e signa l i s route d throug h th e evaporato r thermo - stati c switc h (t o ensur e n o icing ) an d th e trinar y switc h (t o chec k acceptabl e refrigeran t pressure ) befor e [...]

  • Página 459

    Lotu s Servic e Note s Sectio n P H PH. 6 - REFRIGERAN T HANDLIN G Th e syste m i s charge d wit h 0.8 8 k g o f refrigeran t HF C R134a , an d th e followin g precaution s MUS T ALWAY S B E OBSERVED . 1 . O n n o accoun t shoul d refrigeran t eve r b e discharge d t o atmospher e - us e a refrigeran t recovery/recyclin g statio n i n accordanc e w[...]

  • Página 460

    Lotu s Servic e Note s Sectio n XA PH. 7 - REFRIGERAN T PIPEWOR K PRECAUTION S Th e followin g precaution s mus t b e observe d whe n carryin g ou t an y wor k o n th e refrigeran t pipework : Befor e disconnectin g an y refrigeran t pipework , th e refrigeran t mus t firs t b e recovere d usin g suitabl e equip - men t connecte d t o th e servic e[...]

  • Página 461

    200 0 / 0 4 Pag e 1 5[...]

  • Página 462

    PH. 8 - REFRIGERAN T OI L Th e interna l workin g part s o f th e compresso r ar e lubricate d b y refrigeran t oil . Thi s i s a specia l typ e o f oi l whic h ha s a n affinit y wit h th e refrigerant , suc h tha t a proportio n o f th e oi l circulate s wit h th e refrigerant , aroun d th e whol e system . Unde r norma l operatin g conditions , [...]

  • Página 463

    Lotu s Servic e Note s Sectio n P H Tensio n shoul d b e checke d usin g a Clavi s frequenc y mete r T000T1398 F o n only th e lowermos t bel t run . Specification : 13 5 t o 15 0 H z Alternatively , th e bel t i s correctl y adjuste d whe n a forc e o f 1 0 k g (fir m finge r pressure ) a t th e centr e o f th e lowermos t bel t ru n produce s a o[...]

  • Página 464

    Lotu s Servic e Note s Sectio n XA Oi l Quantit y Adjustmen t Prio r t o Compresso r Refitmen t Refitting Existing Compressor i ) I f th e existin g compresso r i s t o b e refitte d afte r norma l refrigeran t recover y ha s bee n performed , a quan - tit y o f oi l equivalen t t o tha t recovere d mus t b e adde d t o tha t alread y hel d i n th [...]

  • Página 465

    Lotu s Servic e Note s Sectio n P H Radiator mounting pane! Condenser support grommet Cooling fan Engine cooling radiator a.c. condenser Condenser mounting frame Fan motor mounting brackets fpTo l 7 . Releas e th e radiato r mountin g pane l fro m th e cras h structur e an d lif t awa y th e complet e assembly . 8 . T o remov e th e condense r fro [...]

  • Página 466

    Lotu s Servic e Note s Sectio n XA PH.1 1 - RECEIVER-DRIE R I f th e syste m ha s bee n ope n t o atmospher e fo r an y lengt h o f time , e.g . followin g acciden t damag e o r a burs t hos e o r damage d component , th e receiver-drie r uni t mus t b e renewed , an d shoul d b e th e las t componen t t o b e fitted , an d uncappe d onl y immediat[...]

  • Página 467

    Lotu s Servic e Note s Sectio n P H PH.1 2 - EXPANSIO N VALV E Th e expansio n valv e i s fitte d ont o th e evaporato r pipe s a t th e fron t o f th e a.c . housin g i n th e climat e chamber , an d i s accessibl e fro m withi n th e fron t service s compartment . T o replac e th e valve : 1 . Recove r th e refrigeran t usin g suitabl e equipmen [...]

  • Página 468

    Lotu s Servic e Note s Sectio n XA PH . 1 3 - EVAPORATO R UNI T Th e a.c . evaporato r i s mounte d i n a housin g whic h include s th e fres h air/recirc . flap , fla p actuator , an d a.c . thermostati c switch . Th e uni t sit s o n foa m pad s i n th e passenge r sid e o f th e chassi s climat e chamber , seale d t o th e fres h ai r an d recir[...]

  • Página 469

    Lotu s Servic e Note s Sectio n P H PH.1 4 - HEATER/BLOWE R FA N ASSEMBL Y Th e heater/blowe r fa n assembl y comprise s th e heate r matrix , ai r blen d fla p an d blowe r fa n an d motor , containe d withi n a rivette d plasti c housing , fitte d i n th e driver' s sid e o f th e chassi s climat e chamber . A pai r o f resistor s use d i n [...]

  • Página 470

    Pag e 2 4 200 0 / 0 4[...]

  • Página 471

    Lotu s Servic e Note s Sectio n OG CLUTC H SECTIO N Q F - M11 1 ELIS E Sub-Sectio n Pag e Genera l Descriptio n QF. 1 2 Adjustmen t QF. 2 3 Hydrauli c Releas e Syste m QF. 3 4 Clutc h Assembl y QF. 4 9[...]

  • Página 472

    Pag e 2 199 8 / 0 2[...]

  • Página 473

    • QF. 1 - GENERA L DESCRIPTIO N Th e drivin g elemen t o f th e clutc h assembl y consist s o f th e rea r fac e o f th e engin e flywheel , an d a pres - sur e plat e fixe d t o th e flywhee l vi a th e sprin g diaphrag m clutc h cove r assembly . Th e drive n element , i s a single , dry , doubl e side d frictio n plate , spline d t o th e gear[...]

  • Página 474

    Lotu s Servic e Note s Sectio n PH Not e tha t n o peda l downsto p i s fitted , an d tha t th e peda l wil l contac t th e peda l bo x befor e th e maste r cylinde r 'bottom s out' . Adjuste d a s above , ful l peda l trave l shoul d produc e a slav e cylinde r pushro d movemen t o f 1 3 -1 5 mm . I f thi s i s no t achieved , blee d th [...]

  • Página 475

    Lotu s Servic e Note s Sectio n OG To overhaul the master cylinder: Clam p th e cylinde r i n a sof t jawe d vice , an d pul l th e rubbe r dus t boo t of f th e cylinde r end . Remov e th e circli p fro m th e en d o f th e cylinder , takin g car e no t t o scratc h th e bor e surface . Remov e th e sto p washe r an d extrac t th e cylinde r inter[...]

  • Página 476

    Lotu s Servic e Note s Sectio n Q F O n reassembly , scrupulou s cleanlines s i s essential . Clea n hand s thoroughl y beforehand . Lubricat e al l seals , th e cylinde r bore , an d al l interna l component s wit h clea n brak e fluid . Fi t th e secondar y sea l int o it s groov e o n th e piston , wit h th e li p toward s th e front . Fi t th e[...]

  • Página 477

    Remov e th e tw o bolt s securin g th e cylinde r t o th e mountin g bracket , an d withdra w th e cylinder . T o refit , revers e th e remova l procedure , tightenin g th e slav e cylinde r mountin g bolt s t o 2 5 Nm . Clea n an d refi t th e speciall y coate d clevi s pi n an d 'R ' pi n t o connec t th e pushro d t o th e releas e lev[...]

  • Página 478

    • Replacin g Hydrauli c Pip e Durin g thi s operation , tak e al l appropriat e precaution s t o protec t agains t damag e cause d b y contaminatio n o f painte d surface s wit h brak e fluid . 1 . Fo r optimu m access , remov e th e lef t han d sid e das h panel s (se e Servic e Note s sub-sectio n BN.12 ) an d th e L H sil l coi n tray . Remov [...]

  • Página 479

    Lotu s Servic e Note s Sectio n OG 5 . O n RH D cars : - Us e a n M1 2 female/M1 2 femal e connecto r t o joi n th e rea r en d o f th e (straightened ) ol d pip e t o th e fron t en d o f th e new . - Dra w th e pipe s throug h int o th e lef t han d sid e o f th e fron t service s compartment , befor e continuin g t o fee d th e pipe s behin d th[...]

  • Página 480

    Lotu s Servic e Note s Sectio n Q F 6 . Releas e th e tw o bolt s securin g th e starte r moto r an d dir t shiel d t o th e clutc h housing . Remov e th e shield , an d withdra w an d suppor t th e starte r motor , takin g car e t o protec t th e liv e starte r moto r lea d fro m ground - ing . 7 . Remov e th e dir t shiel d fro m th e to p fron t[...]

  • Página 481

    Lotu s Servic e Note s Sectio n OG 15 . Examin e th e frictio n plat e fo r oi l contamination , broke n cus h driv e springs , crackin g o f th e sprin g apertures , o r an y othe r damage . Measur e th e overal l thicknes s acros s th e frictio n material ; Ne w thickness : 6. 9 - 7. 4 m m Servic e limit : 5. 6 m m Measur e th e dept h o f th e r[...]

  • Página 482

    22 . Refi t th e transmissio n t o th e engine , engagin g th e gearbo x inpu t shaf t int o th e frictio n plat e splines , an d locatin g th e clutc h housin g ont o th e engin e matin g fac e dowels . 23 . Continu e re-assembl y i n th e revers e orde r t o disassembl y wit h th e followin g notes : - Us e ne w circlip s o n th e spigot s o f th[...]

  • Página 483

    Lotu s Servic e Note s Sectio n OG MOTO R SPOR T SECTIO N X A - ELIS E Sub-Sectio n Pag e Introductio n XA. 1 2 19 0 VHP D Engin e XA. 2 2 Competition/Competitio n Styl e Seat s & 6-Poin t Competitio n Harnes s XA. 3 8 Roll-Ove r Ba r Competitio n Reinforcemen t Ki t XA. 4 1 1 Han d Hel d Fir e Extinguishe r XA. 5 1 4 Plumbed-l n Fir e Extingui[...]

  • Página 484

    Lotu s Servic e Note s Sectio n X A XA. 1 - INTRODUCTIO N Lotu s Car s i s marketin g a rang e o f performanc e product s fo r th e Elise , aime d primaril y a t competitio n and/o r trac k us e o f th e vehicle . Som e o f th e kit s ma y b e use d alone , bu t other s ma y b e recommende d fo r us e onl y i n conjunctio n wit h othe r complimenta[...]

  • Página 485

    Lotu s Servic e Note s Sectio n X A Guidanc e note s fo r fittin g engin e assembl y 1 . Remov e complet e powe r uni t a s detaile d i n Elis e Servic e Note s sub-sectio n EE.3 . 2 . Remov e th e transmissio n an d clutc h (sub-sectio n QF.4) . Th e standar d frictio n plat e an d clutc h cove r ca n b e fitte d t o th e lightweigh t flywhee l o [...]

  • Página 486

    Lotu s Servic e Note s Sectio n X A 5 . 6 . Th e mountin g plat e fo r th e origina l ai r cleane r an d fue l filte r mus t b e cu t dow n t o allo w th e ne w ai r intak e trunkin g t o b e fitted . Fuel filter Remove this portion N Th e ne w carbo n fibr e airbo x draw s col d ai r fro m th e L H ai r intake : Part s Require d Carbo n Fibr e Air[...]

  • Página 487

    Lotu s Servic e Note s Sectio n X A 7 . Fi t ne w engin e breathe r hoses : Part s Require d Breathe r Hos e Ki t A111E0035 J 1 Assembl e th e ca m cove r breathe r pip e assembl y a s show n an d connec t t o th e tw o ca m cove r spigot s an d airbo x grommet . Grommet A082L6181F Adaptor A111E6153S T-piece A111E6152S Hose A111E0032S Clip A111E615[...]

  • Página 488

    Lotu s Servic e Note s Sectio n X A Ol d type ; 1. 6 m m thick , 1 0 m m wide . Late r type ; 2. 0 m m thick , 1 5 m m wide . (C111J0046F ) I f necessary , rive t th e late r typ e bracke t t o th e peda l usin g a 3/16 " dia . 1/2 " reac h po p rivet . 12 . Als o a t th e peda l box , chec k th e specificatio n o f th e throttl e linkag [...]

  • Página 489

    Lotu s Servic e Note s Sectio n X A 16 . Unles s a 2 0 f.p.i . radiato r i s alread y fitted , replac e th e 1 6 f.p.i . radiato r wit h th e late r type . Part s Require d Radiator , engin e cooling , 2 0 f.p.i . A111K0021 F Refe r t o sub-sectio n KF. 4 fo r fittin g details . Not e - Engin e Ai r Filte r Maintenanc e Instructio n Th e IT G foa m[...]

  • Página 490

    Lotu s Servic e Note s Sectio n X A XA. 3 - COMPETITION/COMPETITIO N STYL E SEAT S & 6-POIN T COMPETITIO N HARNES S Th e Competitio n Sea t i s mad e b y Corbea u specificall y fo r th e Elis e fo r rac e trac k use , an d feature s prominen t shoulde r 'wings ' an d raise d sid e bolster s designe d t o provid e maximu m latera l sup[...]

  • Página 491

    Lotu s Servic e Note s Sectio n OG[...]

  • Página 492

    Pag e 1 0[...]

  • Página 493

    Lotu s Servic e Note s Sectio n X A XA. 4 - ROLL-OVE R BA R COMPETITIO N REINFORCEMEN T KI T Thi s ki t i s designe d t o provid e additiona l bracin g t o th e roll-ove r ba r fo r competitio n use , an d allo w th e fitmen t o f th e 6-poin t competitio n sea t bel t harnes s (se e sub-sectio n XA.2) . Th e standar d 3-poin t inerti a ree l sea t[...]

  • Página 494

    Lotu s Servic e Note s Sectio n X A 6 . Fi t th e corne r plat e fixings , usin g th e reinforcin g plat e o n th e undersid e o f th e floor , an d tighte n th e fixing s i n th e followin g order : Wishbon e pivo t bolt ; 4 5 N m a t norma l rid e heigh t M 8 fixings ; 2 2 N m 7 . Fi t th e acces s gromme t i n th e chassi s sid e rai l underside[...]

  • Página 495

    Lotu s Servic e Note s Sectio n X A i t i f ® 5 c " 3 • a « c t o • o 1 0 ? < b I Pag e 1 3[...]

  • Página 496

    Lotu s Servic e Note s Sectio n X A XA. 5 - HAN D HEL D FIR E EXTINGUISHE R - A111T0002 S Recommende d Fittin g Instruction s I t i s recommende d tha t thi s extinguishe r i s mounte d ahea d o f th e passenge r seat , fixe d t o th e cockpi t floo r crossmembe r a s detaile d below : 1 . Mar k th e position s o f th e tw o fixin g hole s i n th e[...]

  • Página 497

    Lotu s Servic e Note s Sectio n X A XA. 6 - PLUMBE D I N FIR E EXTINGUISHE R KI T - A111T0004 S Th e illustratio n overlea f show s th e suggeste d layou t o f thi s fir e extinguishe r ki t fo r us e i n th e Lotu s Elise . Th e bottl e i s secure d t o th e passenge r floo r crossmembe r usin g threade d inserts . A releas e handl e i s mounte d [...]

  • Página 498

    Pag e 1 6[...]

  • Página 499

    Lotu s Servic e Note s Sectio n X A XA. 7 - UNIBAL L TO E LIN K KI T - A111DQ127 S Fo r competition use , especiall y i f slic k tyre s ar e t o b e use d wit h th e associate d increas e i n suspensio n loadings , i t i s recommende d t o replac e th e rea r suspensio n to e contro l link s wit h unibal l typ e links , complet e wit h bracket s wh[...]

  • Página 500

    Lotu s Servic e Note s Sectio n X A XA. 8 - ROA D SPRIN G & DAMPE R SE T - A111C0138 S Roa d spring s an d damper s ar e availabl e a s a vehicl e set , designe d t o b e use d wit h a lowere d rid e heigh t fo r trac k use . Th e fron t spring s ar e uprate d fro m 27. 5 N/m m t o dua l rat e 25/4 0 N/m m springs , an d th e rear s ar e uprate[...]

  • Página 501

    Lotu s Servic e Note s Sectio n X A A t th e lowere d rid e height , th e suspensio n geometr y shoul d b e se t a s follows : Subject Fron t Camber : Fron t Caste r Fron t To e Rea r Camber * Rea r To e Specification -0.3 ° (std . rid e height : - 0.1° ) + 3.8 ° 0. 2 m m to e ou t overal l - 2.0 ° (std . rid e height : - 1.8° ) 1. 2 m m to e [...]

  • Página 502

    Lotu s Servic e Note s Sectio n X A Bas e Setting Standar d to e lin k wit h femal e threade d pivo t balls* : 4 x 1 m m shi m washer s Standar d to e lin k wit h integra l stu d bal l joints : 3x 1 m m shi m washer s Unibal l to e link : 3 x 1 m m shi m washe r abov e join t Whe n changin g rid e height , th e lengt h o f th e to e lin k wil l nee[...]

  • Página 503

    Lotu s Servic e Note s Sectio n X A XA. 9 - FRON T HU B CLAM P BOL T SE T - A111C0137 S Thi s se t i s applicabl e onl y t o car s buil t befor e Sept . 199 7 (approx . VI N W 1830 ) wit h M1 2 fron t hu b clam p bolts . I f th e ca r i s t o b e use d i n a competitio n environmen t wit h th e associate d hig h leve l o f chassi s loading , i t i [...]

  • Página 504

    Lotu s Servic e Note s Sectio n X A XA.1 0 - ADJUSTABL E FRON T ANTI-ROL L BA R - A111C0134 S Fo r competitio n use , a stiffene d tubula r fron t anti-rol l ba r (1 4 gaug e wal l thicknes s replace s 1 7 gauge ) i s availabl e whic h als o provide s a 5 hol e choic e o f dro p lin k attachment . Th e ba r i s a direc t replacemen t fo r th e stan[...]

  • Página 505

    Lotu s Servic e Note s Sectio n X A XA.1 1 - OI L COOLE R KI T - A111K0037 S Th e oi l coole r ki t i s recommende d fo r us e wit h th e 19 0 VHP D engine , an d include s a 9 ro w coole r mounte d t o th e fron t cras h structur e beneat h th e radiato r duct , int o th e floo r o f whic h ar e cu t ai r fee d holes , wit h ai r exhaustin g fro m[...]

  • Página 506

    Lotu s Servic e Note s Sectio n X A Fittin g Procedur e 1 . Replac e th e oi l filte r housin g o n th e engin e wit h th e ne w housin g whic h incorporate s fee d an d retur n port s fo r th e oi l coole r hoses . Transfe r th e oi l filte r canister . Fi t th e ne w blankin g plu g int o th e tappe d hol e i n th e to p o f th e housing . Usin g[...]

  • Página 507

    Lotu s Servic e Note s Sectio n X A hole s i n eac h sid e o f th e cras h structur e fo r th e coole r mountin g channe l fixings , an d secur e th e channel . 5 . Mar k u p an d cu t th e tw o oi l coole r hos e routin g hole s i n th e fron t fac e o f th e bod y R H 'A ' pos t a s show n i n th e diagram . Remov e th e coi n tra y fro[...]

  • Página 508

    Lotu s Servic e Note s Sectio n X A XA.1 2 - BATTER Y ISOLATO R SWITC H KIT S Thi s dua l pol e flic k switc h i s mounte d i n th e cabi n an d operate s th e ignitio n circui t directly , an d vi a a rela y i n th e batter y compartment , al l othe r batter y sen/ices . A n alternato r dum p resisto r i s incorporate d t o protec t th e alternato[...]

  • Página 509

    Lotu s Servic e Note s Sectio n X A 2 . Maste r Switc h Relay : Usin g on e existin g Pulser t i n th e batter y well , mar k u p an d dril l a secon d fixin g hol e 9m m diamete r an d fi t a n M 6 Pulser t A079W6156F . Secur e th e rela y usin g tw o M 6 screws , wit h a 'P ' cli p locate d unde r on e o f th e fixing s t o carr y th e [...]

  • Página 510

    Lotu s Servic e Note s Sectio n X A t o on e o f th e ends , us e splic e crimp , solde r an d heatshrink , t o connec t th e ne w gree n 1. 0 m m wir e leadin g t o th e ne w fus e holde r t o b e attache d t o th e sid e o f th e mai n fusebo x an d equippe d wit h a 10 A fuse . - Inser t int o th e othe r cavit y o f th e ne w fuseholder , th e [...]

  • Página 511

    Lotu s Servic e Note s Sectio n X A 6 . Us e splic e crimp , solde r an d heatshrin k t o connec t th e ne w re d (2. 0 mm ) wir e t o th e alternato r dum p resistor , an d connec t th e othe r en d t o th e maste r switc h rela y termina l wit h th e othe r re-terminate d batter y positiv e cables . 7 . Us e splic e crimp , solde r an d heatshrin[...]

  • Página 512

    Lotu s Servic e Note s Sectio n X A Circui t diagra m - Wit h revise d harnes s E 3 /m Pag e 3 0[...]

  • Página 513

    Lotu s Servic e Note s Sectio n X A XA.1 3 - REMOVEABL E STEERIN G WHEE L - A111H0026 J Th e motorspor t removeabl e steerin g whee l i s a direc t replacemen t fo r th e standar d wheel , an d allow s fo r quic k detachmen t o f th e whee l fo r improve d cabi n access , an d ca n provid e a n increase d measur e o f thef t protection . Th e Mom o[...]

  • Página 514

    Lotu s Servic e Note s Sectio n X A M6 x 20 capscrew A082W7041F Horn slip ring carrier Steering wheel Steering wheel spacer M6 x 16 screw A918W7120F Alignment groove Splined hub Hub spacer Key lock barrel Horn contact adaptor Locking ring Horn push button /m Pag e 3 2[...]

  • Página 515

    XA.1 4 - STAG E 2 (13 5 BHP ) ENGIN E TUN E U P KI T - A/B111E6215 S Thi s ki t comprise s a reworke d cylinde r hea d assembl y an d cas t allo y intak e manifol d an d plenum . I t i s designe d t o b e use d i n conjunction wit h th e competitio n silence r (A111S0037S) , an d fo r trac k use , wit h th e cata - lys t replacemen t pip e (A111S00[...]

  • Página 516

    Lotu s Servic e Note s Sectio n X A -Ai r inle t temperatur e sensor ; - Fue l rai l an d injectors ; - Idl e ai r contro l steppe r motor ; - Throttl e bod y an d breathe r pipes . 5 . Remov e fro m th e ol d cylinde r hea d th e followin g component s fo r re-use : - Ca m bel t tensione r sprin g pedasta l bolt ; - Roto r ar m an d anti-flas h sh[...]

  • Página 517

    Lotu s Servic e Note s Sectio n X A XA.1 5 - YOKOHAM A A038- R COMPETITIO N TYRE S Th e Yokoham a A038- R tyr e ha s bee n jointl y develope d b y Lotu s an d Yokoham a specificall y fo r th e Lotu s Elise , an d whils t th e specificatio n i s optimise d fo r trac k use , th e tyr e i s roa d lega l i n th e U.K . an d Europe . Th e tyr e offer s [...]

  • Página 518

    Lotu s Servic e Note s Sectio n X A XA.1 6 - 340 R 34 0 PS/TONN E PAC K (RHD : A34QX6Q07S . LHD : A340X6014S ) LSL38 9 Th e purpos e o f th e 34 0 ps/tonn e ki t i s t o optimis e th e performanc e potentia l fo r us e o n close d rac e tracks . A majo r par t o f th e packag e involve s th e remova l o f component s t o sav e weight , wit h th e f[...]

  • Página 519

    Lotu s Servic e Note s Sectio n X A Delete IAC valve: Remov e th e idl e ai r contro l valve , mountin g bracke t an d plumbing . Fi t blankin g plug s t o th e inle t trac t spigot s o n manifol d underside . Fi t blankin g gromme t t o backplate . Fit breather hose kit: Remov e th e screenwas h bottl e an d batter y clam p bracke t fro m th e fro[...]

  • Página 520

    Lotu s Servic e Note s Sectio n X A housing s fro m th e topshel l wit h a windscree n remova l pneumati c knife . Fi t th e headlam p blankin g panels t o th e topshel l usin g elastomeri c adhesive . Polycarbonate windscreen: Remov e th e windscreen , an d replac e wit h th e lightweigh t polycarbonat e version . Refe r t o Servic e Note s sub-se[...]

  • Página 521

    Lotu s Servic e Note s Sectio n X A LHD ) bar . Thi s wil l requir e a clearanc e slo t t o b e mad e i n th e engin e li d an d bod y apertur e gutter . A templat e (LSL401 ) fo r th e engin e li d slo t i s provide d wit h th e ba r t o allo w a n initia l fi t t o b e made , wit h initia l dimension s fo r th e bod y apertur e measureabl e fro m[...]

  • Página 522

    XA.1 7 - 340 R OI L COOLE R KI T (A340E0035S ^ LSL38 8 Al l LH D 340R s wer e factor y buil t wit h oi l coolers . Th e followin g procedur e outline s oi l coole r fitmen t t o a RH D 340R , recommende d fo r us e o n rac e track s o r i n conjunctio n wit h th e 340ps/tonn e kit . Fittin g Procedur e 1 . Remov e th e bod y topshel l (se e sub-sec[...]

  • Página 523

    Lotu s Servic e Note s Sectio n X A Qi l Cp<?'e r HP ? ? R<M»n g Heat protective holes in rad. duct outer wall 200 0 / 0 2 Pag e 4 1[...]

  • Página 524

    Lotu s Servic e Note s Sectio n X A XA.1 8 - GOODRIDG E BRAK E HOS E SE T (A34QJ6000S 1 LSL39 8 Th e Goodridg e stee l braide d brak e hos e se t i s a direc t replacemen t fo r th e standar d hoses , wit h th e followin g exception : Th e rea r hose s d o no t us e th e standar d 'P ' cli p o n th e lowe r wishbone , bu t shoul d b e ti [...]

  • Página 525

    Lotu s Servic e Note s Sectio n X A XA.2 0 - REA R RACELIGH T CONVERSIO N KI T (A340M0042K ) LSL39 0 Th e raceligh t conversio n ki t provide s fo r th e Centr e Hig h Mounte d Sto p Lam p (CHMSL ) t o b e use d fo r bot h a brak e lamp , an d als o a raceligh t activate d wit h ignition . 1 . Disconnec t an d remov e th e CHMS L fro m th e topshel[...]

  • Página 526

    XA.2 1 - TONNEA U COVE R CRH D - A340V6000S : LH D - A340V6022S ) Thi s tonnea u cove r i s manufacture d fro m a n Acryli c materia l wit h a polyurethan e coatin g o n th e inside , an d no t fro m Haart z materia l a s state d i n som e sale s literature . Stowag e I t i s importan t tha t th e tonnea u cove r i s no t kep t i n th e storag e ba[...]

  • Página 527

    Lotu s Servic e Note s Sectio n X A 4 . Pus h th e tonnea u hal f roun d das h sectio n int o plac e belo w th e windscree n an d abov e dash . Hol d i n plac e whils t markin g eac h 'A ' pos t fo r th e socke t position . Remov e tonneau , an d dril l a suitabl e hol e i n eac h scree n pilla r fo r th e sel f tappin g pres s stu d sock[...]

  • Página 528

    Lotu s Servic e Note s Sectio n X A XA.2 2 - 34Q R EXCHANG E 19 0 BH P EC M (A340M6026S ) LSL39 4 Th e 19 0 BH P exchang e engin e EC M i s designe d fo r trac k us e only , an d include s th e followin g features : Modifie d fuellin g an d ignitio n maps ; Ope n loo p fuelling; Rp m limi t raise d fro m 7,80 0 t o 800 0 rpm ; Rad . fa n switchin g[...]

  • Página 529

    Lotu s Servic e Note s Sectio n X A 9 . Usin g th e crankshaf t pulle y bolt , slowl y tur n th e crankshaf t 2 turn s clockwis e t o chec k ther e i s n o valve / pisto n contact , an d re-alig n th e timin g mark s withou t havin g t o 'bac k up' . Chec k tha t th e tensione r pointe r i s stil l correctl y aligne d wit h th e inde x wi[...]

  • Página 530

    • XA.2 3 - 340 R TAC H TIME R LEVE L 1 (A34QNQ006S ) LSL39 2 Th e Tac h Time r i s produce d b y Stac k specificall y fo r th e 340R , an d consist s o f a replacemen t tachomete r wit h a n LC D pane l t o displa y th e availabl e feature s whic h include : Multi-leve l shif t light ; La p time s (incl . memor y an d split) ; Acceleratio n times[...]

  • Página 531

    Lotu s Servic e Note s Sectio n X A 200 0 / 0 2 Pag e 4 9[...]

  • Página 532

    Lotu s Servic e Note s Sectio n X A XA.2 4 - 340 R COMPETITIO N ROL L OVE R BA R (RHP : A340A0036S . LHD : A340A0037S ) LSL40 1 Th e drive r only , competitio n rol l ove r ba r i s availabl e fo r RH P o r LH P cars , an d i s RA C approve d fo r competitio n us e i n th e U.K . provide d tha t a passenge r sea t i s no t fitte d i n th e vehicle [...]

  • Página 533

    200 0 / 0 2 Pag e 5 1[...]

  • Página 534

    Lotu s Servic e Note s 340 R 340 R SUPPLEMEN T Sub-Sectio n Pag e Introductio n 340R. # 2 Technica l Dat a 340R.T D 2 Chassis 340R. A 3 Bod y 340R. B 4 Fron t Suspensio n 340R. C 8 Rea r Suspensio n 340R. D 9 Engin e 340R. E 9 Transmissio n 340R. F 1 6 Wheel s & Tyre s 340R. G 1 7 Steerin g 340R. H 1 8 Brakin g 340R. J 1 8 Coolin g 340R. K 1 8 [...]

  • Página 535

    Lotu s Servic e Note s 34 0 H 340R. # - INTRODUCTIO N Th e Elis e 340 R mad e it s debu t a t th e 199 8 Birmingha m Moto r Sho w a s a radica l lightweigh t sportsca r concept , focuse d o n pur e drivin g pleasure . Minima l change s wer e require d t o mee t Europea n homologatio n regulations , an d th e ca r commence d productio n i n Januar y[...]

  • Página 536

    Lotu s Servic e Note s 34 0 H 34QR. A - CHASSI S Th e bonde d aluminiu m allo y chassi s structur e i s derive d fro m th e standar d Elis e chassis , bu t ha s n o doo r hing e mountings , an d th e sil l to p edg e suppor t flange s ar e replace d b y channe l strip s t o moun t th e cockpi t sid e screens . Th e galvanise d stee l rea r subfram [...]

  • Página 537

    Lotu s Servic e Note s 34 0 H 340R. B - BOD Y Th e non-structura l composit e bod y structur e i s minimalis t an d functional , wit h th e exceptionall y ligh t weigh t contribute d t o b y th e exclusio n o f openin g door s o r a roo f structure . Th e principa l bod y moulding s ar e a s follows : Cockpit Tub: Singl e piec e mouldin g include s[...]

  • Página 538

    Lotu s Servic e Note s 340 R 200 0 / 0 2 Pag e 5[...]

  • Página 539

    Lotu s Servic e Note s 34 0 H Remova l o f Topshel l Th e bod y topshel l i s secure d b y threade d fasteners . Remova l o f th e topshel l require s als o tha t th e seat s b e remove d an d th e rol l ove r ba r fixing s release d t o allo w th e ba r t o b e tilte d forwards . 1 . Remov e th e rea r aerofoi l fro m th e mountin g plates . 2 . R[...]

  • Página 540

    Lotu s Servic e Note s 340 R 7 . Remov e th e singl e fixin g securin g th e fron t bod y spin e t o th e plint h belo w th e wipe r spindle . 8 . Remov e th e fron t undertray . 9 . Remov e th e tw o screw s a t eac h sid e securin g th e topshel l t o th e undersid e o f th e sid e sil l behin d th e fron t wheels , an d th e singl e adjacen t sc[...]

  • Página 541

    340R. C - FRON T SUSPENSIO N Th e 340 R i s fitte d wit h th e Elis e Spor t suspensio n packag e whic h include s adjustabl e sprin g platfor m Kon i damper s wit h th e shorte r an d stiffe r springs , an d th e uprate d fron t anti-rol l ba r i n Nylo n chassi s mountin g blocks . Standar d Elis e wishbone s ar e used , bu t ar e powde r coate d[...]

  • Página 542

    Lotu s Servic e Note s 34 0 H 340R. D - REA R SUSPENSIO N Th e 340 R i s fitte d wit h th e Elis e Spor t suspensio n packag e whic h include s adjustabl e sprin g platfor m Kon i damper s wit h th e shorte r an d stiffe r springs . Standar d Elis e forge d stee l hu b carrier s an d wishbone s ar e used , wit h th e wishbones , 'integra l stu[...]

  • Página 543

    Pag e 1 0[...]

  • Página 544

    Lotu s Servic e Note s 34 0 H g > M > c < 0 < D S * « v c o . 2 c o o o ( 0 c 4 > o < n S- o 0 ) 2h £ a > £ o a > rt, w o S. 2 O (/ > C < D c . 2 7 3 § £ S o 4 > C O •2> > > o o w w a j a > w w 0 . O < a •— • C Q a > w 5 2 > ( 0 3 ( 0 (/ ) £ $ Q - g.j c < c 1 2 4 > w £ E . g[...]

  • Página 545

    Lotu s Servic e Note s 34 0 H Engin e Managemen t Th e engin e managemen t electroni c controlle r i s commo n wit h th e Espri t V 8 an d use s som e o f tha t model' s components , including : Idl e Ai r Contro l (IAC ) valve ; mounte d o n th e rea r o f th e engin e an d connecte d b y hos e betwee n th e intak e airbo x backplat e an d po[...]

  • Página 546

    Lotu s Servic e Note s 34 0 H Intake System & Resonator Valve: A ne w shor t intak e manifol d assembl y incorporate s individua l inle t trac t butterfl y throttle s operate d vi a cabl e quadran t betwee n cylinder s 2 & 3 . A carbo n fibr e airbox , bigge r stil l tha n th e Spor t 19 0 version , i s supplie d wit h ai r vi a larg e diam[...]

  • Página 547

    Lotu s Servic e Note s 34 0 H Th e sequenc e o f operatio n i s a s follows : a) . Norma l runnin g - Bot h solenoi d valve s of f - Fla p valv e ope n Th e fla p capsul e i s vente d t o at - mosphere , an d th e fla p valv e i s sprun g open . Inle t manifol d seale d b y th e lock - in g capsule . b) . Cruisin g a t 3 0 mp h i n secon d o r thir[...]

  • Página 548

    Lotu s Servic e Note s 34 0 H Air Cleaner Th e Elis e 340 R use s tw o identica l Pipercros s conica l foa m ai r cleane r element s containe d withi n th e ai r intak e trunking ; a primar y filte r mounte d a t th e inle t en d o f th e trunking , an d a secondar y filte r mounte d immediatel y afte r th e resonato r valv e a t entranc e t o th e[...]

  • Página 549

    Lotu s Servic e Note s 34 0 H 34QR.F - TRANSMISSIO N Th e 340 R use s th e sam e clos e rati o transmissio n a s i s fitte d t o th e Elis e 111S . Compare d wit h th e standar d transmission , th e fina l driv e i s lowere d fro m 3.94: 1 t o 4.20:1 , i n conjunctio n wit h raise d firs t an d secon d ratios , an d a lowere d fifth . Th e mph/100 [...]

  • Página 550

    Lotu s Servic e Note s 340 R 340R. G - WHEEL S & TYRE S Th e 340 R uses , accordin g t o market , eithe r specia l Lotu s style d 1 0 spok e magnesiu m wheels , mad e b y Tecnomagnesio , o r 1 0 spok e allo y wheel s mad e b y Rimstock . Bot h type s ar e mounte d o n standar d Elis e hub s usin g longe r (42m m protrusio n instea d o f 36mm ) [...]

  • Página 551

    34QR. H - STEERIN G Al l th e steerin g component s use d o n th e 340 R ar e a s standar d Elise , excep t th e steerin g whee l centr e pa d whic h i s trimme d i n blu e Alcantara , an d th e rac k positionin g plate s whic h ar e 'sport ' specificatio n t o sui t th e lowere d rid e height . Th e Spor t removeabl e whee l ma y b e fit[...]

  • Página 552

    Lotu s Servic e Note s 34 0 H 340. M - ELECTRICA L VEHICL E SECURIT Y Th e 340 R use s a Met a securit y syste m a s eithe r a n M3 6 T 2 electroni c immobilise r meetin g Thatcha m categor y 2 requirements , or , a s a n optiona l upgrade , a ful l M9 9 T 2 alar m syste m incorporatin g M2 3 cockpi t intrusio n sensin g an d a sel f powere d siren[...]

  • Página 553

    Lotu s Servic e Note s 34 0 H Whe n triggered , th e electroni c sire n wil l soun d an d th e hazar d warnin g lamp s wil l flas h fo r a perio d o f approximatel y 3 0 second s befor e closin g dow n an d resetting , read y fo r an y furthe r triggerin g input . I f a trigge r i s continuousl y present , th e alar m wil l repea t afte r a shor t [...]

  • Página 554

    Lotu s Servic e Note s 34 0 H Disconnectin g th e Vehicl e Batter y Befor e disconnectin g th e battery , ensur e tha t th e alar m syste m i s disarmed . O n reconnectio n o f th e battery , th e alar m wil l automaticall y b e set . Hav e th e transmitte r read y t o disarm . Componen t Locatio n Th e alar m syste m component s ar e locate d a s [...]

  • Página 555

    • Shift light Seat belts Battery charging Main beam Heated windsci Rearfot Turn lamps Oil pressure Brakes reSTfl Batter y Chargin g Tel l Tal e (red ) Thi s re d tel l tal e wil l ligh t wheneve r th e ignitio n i s o n an d th e engin e i s stopped . I f i t light s an y tim e tha t th e engin e i s running , th e batter y i s no t bein g charge[...]

  • Página 556

    Lotu s Servic e Note s 34 0 H Instrument s Speedomete r Thi s instrumen t displays , i n analogu e form , vehicl e roa d spee d i n eithe r MP H (wit h a secondar y scal e i n km/h) , o r km/ h accordin g t o territory . Recalibratio n o f th e needl e positio n wil l occu r durin g a thre e secon d period followin g ignitio n switc h on . Th e ins[...]

  • Página 557

    Lotu s Servic e Note s 34 0 H uppermos t switc h o n th e cockpi t divider . Not e tha t thi s dua l functio n butto n als o control s th e pane l illuminatio n - se e 'Instrumen t & Switc h Illumination' . Fasci a Switche s Th e cockpi t centra l divid e contain s fiv e pus h butto n switches , eac h o f whic h i s presse d onc e t o[...]

  • Página 558

    vM Lotu s Servic e Note s 340 R Th e heatin g o f th e fron t windscree n i s selecte d b y th e lower-mos t switc h i n th e cockpi t centra l divide . Th e switc h i s operativ e onl y whe n th e engin e i s running , wit h a yello w tel l tal e ico n i n th e tachomete r fac e indicatin g whe n th e circui t i s active . Th e heatin g element s [...]

  • Página 559

    vM Lotu s Servic e Note s 340 R Fuses & Relays Th e mai n fusebo x i s locate d i n th e pas - senge r footweli . an d i s protecte d b y a clea r plasti c cover . Twent y tw o slot s ar e provide d fo r 'Littel ' typ e fuses , whic h ar e numbere d an d coloure d accordin g t o thei r amperag e rating , an d ma y b e pulle d ou t fro[...]

  • Página 560

    Headlam p Cluste r Bul b Replacemen t Eac h headlam p cluste r contain s a centrall y mounte d di p bea m headlamp/sid e marke r lam p unit , a to p mounte d tur n indicato r lamp , an d a n unli t len s a t th e botto m comer . Fo r acces s t o th e headlam p cluste r bulbs , a n acces s pane l i s provide d i n th e topshel l abov e th e fron t s[...]

  • Página 561

    vM Lotu s Servic e Note s 340 R 340 R CIRCUI T DIAGRA M INDE X Circui t Starter , Alternator , Ignitio n Fue l Pump , Ignitio n Coi l Radiato r Fan , EC M Contro l EC M Powe r Supply , Sensor s Wipe r Moto r Tur n Indicators , Hazar d Lamp s Heate d Fron t Scree n Instrumen t Controlle r Met a Immobilise r Met a Alar m Headlamp s Sidelight s Auxili[...]

  • Página 562

    vM Lotu s Servic e Note s 340 R BATTER Y Pag e 2 9[...]

  • Página 563

    vM Lotu s Servic e Note s 340 R 2 9 4 9 5 3 1 2 2 3 5 5 8 E.C. M shee t 2 Pag e 3 0[...]

  • Página 564

    vM Lotu s Servic e Note s 340 R 7 5 > 1 5 7 8 5 8 0 8 4 8 2 1 1 5 4 8 4 7 E.C. M RP M DRO P SWITC H NOT E NO T FITTE D T O STANDAR D 340 R shee t 3 _ _ Pag e 3 1[...]

  • Página 565

    vM Lotu s Servic e Note s 340 R Pag e 3 2[...]

  • Página 566

    BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D Page 3 3[...]

  • Página 567

    vM Lotu s Servic e Note s 340 R iwAm^mu^ BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D INST R (19 ) ( J AH C (2 ) U BUL K 4 0 r * > • AH C (3 ) INST R (20 ) HAZAR D SWITC H M D. I SWITC H SPLIC E E (GW ) SPLIC E F (GR ) FHC 1 CA V 1 < * L H LH C rtCA V I FH C 2 CA V 1 n BUL K 3 9 G W R H SID E LIGH T CON N CA V 4 SPLIC E W n R H LIGH T CON N[...]

  • Página 568

    vM Lotu s Servic e Note s 340 R •BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D N FUS E A H 2 5 am p P HEATE D FRON T SCREE N RELA Y INSTRUMEN T CONTROLLE R CAV1 2 SE E SHEE T 8 HEATE D FRON T SCREE N shee t 7 Pag e 3 5[...]

  • Página 569

    vM Lotu s Servic e Note s 340 R BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D FUS E A S 1 0 am p ALAR M SE E SHEE T 1 0 SE E SHEE T 1 4 EC M PI N 5 a ENGIN E SPEE D $ VOLT S [> - VEHICL E SPEE D SENSO R BUL K 3 7 - i CAV E fS _ (J«M«f ) v WATE R TEM P f . SENDE R I OPTIO N SWITC H HEADLAMP S SE E SHEE T 1 1 BUL K 4 3 • O- ~?cc9 ~ HIG H BEA M [...]

  • Página 570

    vM Lotu s Servic e Note s 340 R IGNITIO N UNFUSE D IGNITIO N FUSE D SPLIC E B SE E SHEE T SPUCE E IG N COI L 0 2 SENSO R FUS E B 4 7. 5 am p NO T USE D BULK S IMHC 1 B | IMH C 5 I B STARTE R SO L IMH C 1 2 V IMH C 5 V SE E SHEE T 1 SE E SHEE T 1 _IMHC£ _ 3 B jAH C AH C 1 3 rt AH C 1 4 ^ 'O ' ^ ^ SE E SHEE T 1 0 ALAR M shee t 9 Page 3 7[...]

  • Página 571

    vM Lotu s Servic e Note s 340 R BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D FUS E A S 1 0 am p • OPTIO N SIRE N CONN FUS E A 2 9 am p SE E SHEET * SPLIC E E n AH C 8 BUL K 3 4 CHMS L H C — C • C • K REA R BOO T U D SWITC H OPTIO N FHC 5 - C FRON T BONNE T SWITCHE S OPTION S SE E SHEE T • SPUC E F AH C 2 G R AH C 1 1 — C — AH£1 S FUS[...]

  • Página 572

    vM Lotu s Servic e Note s 340 R BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D Page 3 9[...]

  • Página 573

    BATTER Y IGNITIO N UKIFUSE D Pag e 4 0[...]

  • Página 574

    IGNITIO N UNFUSE D — i •— - > IGNITIO N FUSE D > FUS E A H 3 0 am p P AUXILIAR Y SOCKE T RELA Y NOTE : SOCKET S WIL L ONL Y OPERAT E ABOV E 2000RP M INSTRUMEN T CONTROLLE R CA V 2 7 SE E SHEE T 8 AUXILIAR Y SOCKET S = shee t 1 3 Page 4 1[...]

  • Página 575

    vM Lotu s Servic e Note s 340 R BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D FUS E A1 0 7. 5 am p HOR N RELA Y > SPLIC E C (FUS E AS ) Pag e 4 2[...]

  • Página 576

    vM Lotu s Servic e Note s 340 R BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D FUS E A S 3 am p SE E SHEE T 3 SPLIC E B FUS E A 3 7. 5 am p FUS E A 1 Sam p REA R FO G RELA Y unde r das h R H LH C 2 ) L L H LH C 2 ) CHMS L 2 FO G H C W FO G H C (2 ) J J shee t 1 5 Page 4 3[...]

  • Página 577

    Pag e 4 4[...]

  • Página 578

    vM Lotu s Servic e Note s 340 R Pag e 4 5[...]

  • Página 579

    vM Lotu s Servic e Note s 340 R 340R. Q - MAINTENANC E & LUBRICATIO N Lubricant s ar e a s fo r standar d Elise . Th e maintenanc e schedul e i s basicall y th e sam e excep t th e distanc e interva l i s reduce d fro m 9,00 0 mile s (15,00 0 km) , t o 6,00 0 mile s (10,00 0 km ) t o reflec t th e likel y harde r us e o f th e vehicle . Fo r no[...]

  • Página 580

    • MAINTENANC E SCHEDUL E - ELIS E 34Q R Date : Owner' s Name : Vehicle : Vehicl e Registratio n No. : V.I.N. : Recorde d Mileage : Month s Sinc e Las t Service : Jo b No. : EXPLANATOR Y NOTES ; Require d Maintenanc e I n orde r t o maintai n warrant y validatio n an d hel p ensur e prope r safety , emission s performanc e an d depend - abili[...]

  • Página 581

    vM Lotu s Servic e Note s 340 R SERVIC E TYP E | O p No . OPERATIO N DESCRIPTIO N Afte r Sale s A B C Othe r Nerval s 1 Fi t protectiv e cover s t o seats , footwells , steerin g whee l & rea r bod y X X X X lllllllJllISS ^ M l 2 Rene w engin e oi l & filter * X X X X 3 Inspec t engin e & transmissio n fo r oi l leak s X X X X 4 Chec k [...]

  • Página 582

    vM Lotu s Servic e Note s 340 R O p No . OPERATIO N DESCRIPTIO N SERVIC E TYP E | O p No . OPERATIO N DESCRIPTIO N Afte r Sale s A B C Othe r Interval s O p No . M M - ' • . • '•• • m 2 7 Inspec t tyr e conditio n & se t pressure s X X X X 2 8 aw**. / 2 8 Chec k batter y terminal s fo r securit y & conditio n X X X 2 9 I[...]

  • Página 583

    vM Lotu s Servic e Note s 340 R 340R. P - HEATIN G A rudimentar y heate r i s provide d i n th e for m a ho t ai r duc t linkin g a portio n o f th e engin e radiato r outle t airflo w t o th e vent s a t th e fron t o f th e footwells . Not e tha t th e windscree n i s electricall y heate d (se e sectio n M) . 34QR. Q - CLUTC H Th e clutc h use d [...]

  • Página 584

    Lotu s Servic e Note s Exig e EXIG E SUPPLEMEN T Sub-Sectio n Pag e Introductio n EXIGE. # 2 Technica l Dat a EXIGE.T D 3 Chassi s EXIGE. A 5 Bod y EXIGE. B 5 Fron t Suspensio n EXIGE. C 9 Rea r Suspensio n EXIGE. D 9 Engin e EXIGE. E 9 Transmissio n EXIGE. F 1 7 Wheel s & Tyre s EXIGE. G 1 8 Steerin g EXIGE. H 1 9 Brake s EXIGE. J 1 9 Coolin g[...]

  • Página 585

    Lotu s Servic e Note s Exig e EXIGE. # - INTRODUCTIO N Th e Lotu s Exig e mad e it s publi c debu t a t Brand s Hatc h i n Apri l 2000 , a s a full y roa d goin g versio n o f th e ca r use d i n th e Lotu s Motorspor t Elis e rac e series . Th e ca r i s base d o n th e standar d Elis e chassi s an d cor e bod y structure , bu t usin g th e 17 8 b[...]

  • Página 586

    Lotu s Servic e Note s EXIG E .T P - TECHNICA L DAT A Tyre s -Typ e - Siz e - fron t - rea r - pressur e (cold ) - fron t - rea r Yokoham a A03 9 195/5 0 R1 6 84 V LT S 225/4 5 R1 7 90 W LT S 1. 6 ba r (2 3 lb/in 2 ) 1. 8 ba r (2 6 lb/in 2 ) Exig e Wheel s Typ e Ligh t alloy , 1 2 spok e Siz e - fron t 7 J x 1 6 ET 7 -rea r 8.5Jx17ET 5 Whee l nu t [...]

  • Página 587

    Lotu s Servic e Note s Rea r Suspensio n Typ e Rid e heigh t (fo r geometr y check ) Cambe r Alignmen t - fron t - rea r Engin e Typ e designatio n Cylinde r configuratio n Capacit y Bor e Strok e Compressio n rati o Firin g orde r Spar k plug s Spar k plu g ga p Maximu m engin e spee d Fue l requiremen t Fue l syste m Valv e clearance s (cold ) Ma[...]

  • Página 588

    EXIG E A-CHASSI S Th e Exig e allo y chassi s tub , composit e fron t cras h structure , stee l rol l ove r ba r an d stee l rea r subfram e ar e al l unchange d fro m standar d Elise , bu t th e earlie r typ e o f boo t floo r arrangemen t i s use d wit h a n allo y floo r pane l rivette d betwee n th e rea r longerons . EXIGE . B - BOD Y Th e Exi[...]

  • Página 589

    Lotu s Servic e Note s Exig e T o remove : 1 . Remov e bot h fron t roa d wheel s an d wheelarc h liners . 2 . A t eac h side , remov e th e M 8 fixin g securin g th e clamshel l t o th e sil l fron t extensio n panel . 3 . Remov e th e singl e M 8 scre w securin g eac h to p rea r come r o f th e clamshel l t o a bracke t a t th e to p o f th e &a[...]

  • Página 590

    Lotu s Servic e Note s Exig e 'B'post inboard fixing Door aperture II! /'(( rear Gutter to engine bay surround ' Tank bay closing panel to clam lower edge Support plates to longerons Licence plate recess to tray extension Wheelarch to sill 12 . Carefull y eas e apar t th e tw o fron t section s o f th e clamshel l a s th e shel [...]

  • Página 591

    Lotu s Servic e Note s Exig e releas e th e fixing s securin g th e to p fron t corner s o f th e rea r clamshel l t o rea r bulkhead ; remov e th e heade r rai l clam p fro m insid e th e fron t o f th e roof ; releas e th e over-centr e latche s clampin g th e rea r o f th e roo f t o th e uppe r rea r bulkhead , an d lif t of f th e roo f panel [...]

  • Página 592

    Lotu s Servic e Note s Exig e EXIGE. C - FRON T SUSPENSIO N Th e Exig e i s fitte d wit h th e Elis e Spor t suspensio n packag e whic h include s adjustabl e sprin g platfor m Kon i damper s wit h Exig e specifi c springs , an d th e uprate d fron t anti-rol l ba r i n Nylo n chassi s mountin g blocks . Th e standar d settin g fo r th e fron t ant[...]

  • Página 593

    'ag e 1 0 200 0 / 0 3[...]

  • Página 594

    Lotu s Servic e Note s Exig e Ke v to engine management component location diagram 1 . Evaporativ e emissio n (charcoal ) caniste r 2 . Fue l pum p assembl y 3 . Electroni c Contro l Modul e (ECM ) 4 . Engin e Coolan t Temperatur e (ECT ) senso r (brown ) 5 . Coolan t temperatur e gaug e sende r (blue ) 6 . Oxyge n senso r 7 . Crankshaf t positio n[...]

  • Página 595

    Lotu s Servic e Note s Exig e Engin e Managemen t Th e engin e managemen t electroni c controlle r i s commo n wit h th e Espri t V 8 an d use s som e o f tha t model' s components , including : Idl e Ai r Contro l (IAC ) valve ; mounte d o n th e rea r o f th e engin e an d connecte d b y hos e betwee n th e intak e airbo x backplat e an d po[...]

  • Página 596

    Lotu s Servic e Note s Exig e Intake System & Resonator Valve: A shor t intak e manifol d assembl y incorporate s individua l inle t trac t butterfl y throttle s operate d vi a cabl e quadran t betwee n cylinder s 2 & 3 . A glassfibr e composit e airbox , bigge r stil l tha n th e Spor t 19 0 version , i s supplie d wit h ai r vi a larg e d[...]

  • Página 597

    Lotu s Servic e Note s Exig e Th e sequenc e o f operatio n i s a s follows : a) . Norma l runnin g - Bot h solenoi d valve s of f - Fla p valv e ope n Th e fla p capsul e i s vente d t o at - mosphere , an d th e fla p valv e i s sprun g open . Inle t manifol d seale d b y th e lock - in g capsule . Vacuum Vacuum b) . Cruisin g a t 3 0 mp h i n se[...]

  • Página 598

    Lotu s Servic e Note s Exig e Breather hoses, vacuum Pine s & IAC To MAP sensor & intake resonator control system Purge rail To charcoal canister purge port Breather connection to backplate IAC connection to backplate IAC stepper motor Fuel pressure regulator valve connection IAC connection to underside of throttle bodies Air Cleaner: Th e [...]

  • Página 599

    Lotu s Servic e Note s Exig e Exhaust System: Th e Exig e an d 340 R us e a specia l exhaus t manifol d fabricate d fro m 45m m stee l tube , leadin g vi a a shor t flexibl e sectio n t o th e standar d catalyti c converter , an d the n int o th e transvers e muffler . Th e Exig e muffle r i s base d o n tha t o f th e 340R , th e bod y o f whic h [...]

  • Página 600

    Lotu s Servic e Note s Exig e EXIGE. F - TRANSMISSIO N Th e Exig e use s th e sam e clos e rati o transmissio n a s i s fitte d t o th e Elis e 111S . Compare d wit h th e standar d Elis e transmission , th e fina l driv e i s lowere d fro m 3.94: 1 t o 4.20:1 , firs t an d secon d gea r ratio s ar e raised , an d fift h i s lowered . Compare d wit[...]

  • Página 601

    EXIGE. G - WHEEL S & TYRE S Th e Exig e use s allo y roa d wheel s mad e b y Rimstoc k an d featurin g th e 1 2 - spoke , blac k finish , desig n use d o n th e rac e serie s cars . Whee l diameters , a t 1 6 an d 1 7 inche s fron t an d rear , ar e increase d b y on e inc h ove r standar d Elise , wit h ri m width s o f 7 an d 8. 5 inches . Lo[...]

  • Página 602

    Lotu s Servic e Note s Exig e EXIGE. H - STEERIN G Al l th e steerin g component s use d o n th e Exig e ar e a s standar d Elise , excep t fo r th e rac k positionin g plate s whic h ar e 'sport ' specificatio n t o sui t th e lowere d rid e height . Th e Spor t removeabl e steerin g whee l ma y b e fitte d fo r trac k use . Fo r furthe [...]

  • Página 603

    Lotu s Servic e Note s Exig e EXIGE. M - ELECTRICA L VEHICL E SECURIT Y Th e Exig e use s th e sam e vehicl e Met a securit y syste m a s i s use d o n 340R , bein g eithe r a n M3 6 T 2 electroni c immobilise r meetin g Thatcha m categor y 2 requirements , or , a s a n optiona l upgrade , a ful l M9 9 T 2 alar m syste m incorporatin g M2 3 cockpi [...]

  • Página 604

    Lotu s Servic e Note s Exig e Arming the Alarm Remov e th e ignitio n ke y an d chec k tha t th e doors , tailgat e an d fron t bonne t ar e closed . Pres s th e transmitte r butto n fo r abou t tw o seconds . Thi s comman d wil l b e acknowledge d by : Tw o flashe s o f th e hazar d warnin g lamps ; Th e tel l tal e ahea d o f th e gea r leve r li[...]

  • Página 605

    Lotu s Servic e Note s Exig e Transmitte r Ke y Batter y Replacemen t Th e batterie s fo r th e ke y hea d transmitter s shoul d b e renewe d a t si x monthl y interval s t o ensur e continuit y o f operation . T o replac e transmitte r battery : a) . Us e a thi n blad e t o pris e apar t th e tw o halve s o f th e transmitte r ke y head , an d wit[...]

  • Página 606

    Lotu s Servic e Note s Exig e AUDI O EQUIPMEN T Al l car s ar e fitte d wit h a standar d Elis e amplifie r typ e aeria l mounte d o n th e roo f ai r duct , an d wire d t o a connecto r plu g behin d th e fascia . Th e factor y optio n o f a n audi o fittin g ki t comprise s a pai r o f speaker s mounte d i n th e rea r bulkhead , an d wire d t o [...]

  • Página 607

    Lotu s Servic e Note s Exig e Fuse s & Relay s Th e mai n fusebo x i s locate d i n th e fron t serv - ice s compartment , o n th e passenge r side , an d i s protecte d b y a clea r plasti c cover . Twent y tw o slot s ar e provide d fo r 'Littel ' typ e fuses , whic h ar e numbere d an d coloure d accordin g t o thei r amperag e rat[...]

  • Página 608

    Fuel pump, injectors Engine management, OBDi Engine man. canister purge idle control s Ignition coil- Alarm microwave sensor Engine management controller >Ne Alarm system immobiliser OBD2 connector Engin e |||||( . ^ Fuel pump Injectors Starter solenoid Engine management ignition supply Pag e 2 5[...]

  • Página 609

    Lotu s Servic e Note s Exig e EXIG E CIRCUI T DIAGRA M INDE X Circui t Starter , Alternator , Ignitio n Fue l Pump , Ignitio n Coi l Radiato r Fan , EC M Contro l EC M Powe r Supply , Sensor s Wipe r Moto r Tur n Indicators , Hazar d Lamp s Radi o & Ciga r Lighte r Instrumen t Pac k Met a Immobilise r Met a Alar m Headlamp s Sidelight s Hor n R[...]

  • Página 610

    Lotu s Servic e Note s Exig e 200 0 / 0 3 Pag e 2 7[...]

  • Página 611

    Lotu s Servic e Note s Exig e Pag e 2 8 200 0 / 0 3[...]

  • Página 612

    Lotu s Servic e Note s Exig e 9nn n / n * Pag e 2 9[...]

  • Página 613

    Lotu s Servic e Note s Exig e Pag e 3 0 200 0 / 0 3[...]

  • Página 614

    Lotu s Servic e Note s Exig e 200 0 / 0 3 Pag e 3 1[...]

  • Página 615

    Lotu s Servic e Note s Exig e Pag e 3 2 200 0 / 0 3[...]

  • Página 616

    Lotu s Servic e Note s Exig e 200 0 / 0 3 Pag e 3 3[...]

  • Página 617

    Lotu s Servic e Note s Exig e Pag e 3 4 200 0 / 0 3[...]

  • Página 618

    Lotu s Servic e Note s Exig e EXIGE IMMOBILISER BATTER Y IGNITIO N UNFUSE D IGNITIO N FUSE D IGNITIO N STAR T DROP-OU T -STO5B W SE E SHEE T 1 SPLICE S SE E SHEE T ^ IMH$10 * STARTE R ' SO L IMH C 1 2 IMH C 8 U SE E SHEE T 1 O AH C 1 3 o AH C 1 4 K W ^ V V ^ SE E SHEE T 1 0 ALAR M sheet 9 CHASSI S 200 0 / 0 3 Pag e 3 5[...]

  • Página 619

    Lotu s Servic e Note s Exig e Pag e 3 6 200 0 / 0 3[...]

  • Página 620

    Lotu s Servic e Note s Exig e 200 0 / 0 3 Pag e 3 7[...]

  • Página 621

    Lotu s Servic e Note s Exig e Pag e 3 8 200 0 / 0 3[...]

  • Página 622

    Lotu s Servic e Note s Exig e 200 0 / 0 3 Pag e 3 9[...]

  • Página 623

    Lotu s Servic e Note s Exig e Pag e 4 0 200 0 / 0 3[...]

  • Página 624

    Lotu s Servic e Note s Exig e EXIGE, Q - MAINTENANC E & LUBRICATIO N Th e servic e interva l fo r standar d Elis e an d Elis e 111 S model s i s 9,00 0 mile s (15,00 0 km) . Fo r 340R , Spor t 16 0 an d Exig e models , th e interva l i s 6,00 0 mile s (10,00 0 km) . Maintenanc e Schedul e LSL34 8 ha s bee n update d t o 'D ' leve l t [...]