Lotus Elise (1996) manual

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

Pag e 2[...]

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[...]

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[...]

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[...]

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[...]

• 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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

• - 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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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 [...]

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 .[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 % [...]

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[...]

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 . [...]

• 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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 ([...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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&[...]

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[...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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

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

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

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

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 [...]

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

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[...]

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

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[...]

O N AN D OPERATIO N[...]

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 [...]

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

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 °[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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°[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 . [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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 : [...]

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[...]

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 [...]

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 = [...]

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 . [...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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.[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 ( [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

ENGIN E 8 4 OVERHAU L[...]

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[...]

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[...]

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 ,[...]

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 [...]

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 [...]

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 [...]

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 .[...]

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[...]

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 [...]

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 [...]

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.[...]

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 [...]

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[...]

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[...]

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. [...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 .[...]

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[...]

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 . [...]

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[...]

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[...]

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[...]

• 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 [...]

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 [...]

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[...]

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[...]

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[...]

• 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[...]

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[...]

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 . [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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' ; - [...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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

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

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 . &[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 -[...]

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[...]

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[...]

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 [...]

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 [...]

• 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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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

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

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

'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 [...]

'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[...]

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

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

'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[...]

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

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

'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 ( [...]

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

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

'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[...]

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

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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

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[...]

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

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

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[...]

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[...]

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[...]

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

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

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

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

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[...]

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

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

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[...]

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[...]

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[...]

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[...]

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

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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

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 , [...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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[...]

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 [...]

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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[...]

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• 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[...]

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 [...]

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[...]

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[...]

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[...]

• 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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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

Pag e 1 0[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

Pag e 1 6[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

• 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[...]

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

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 [...]

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

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 [...]

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[...]

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 [...]

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[...]

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

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[...]

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[...]

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[...]

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[...]

Pag e 1 0[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 ) [...]

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[...]

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[...]

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 [...]

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 [...]

• 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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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

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[...]

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[...]

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

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

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[...]

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[...]

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 [...]

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[...]

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[...]

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

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

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[...]

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[...]

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[...]

Pag e 4 4[...]

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

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[...]

• 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[...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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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[...]

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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 [...]