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Manual Lotus Elise (1996)

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  • Lotus Elise (1996) - page 1

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

  • Lotus Elise (1996) - page 2

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

  • Lotus Elise (1996) - page 3

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

  • Lotus Elise (1996) - page 4

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

  • Lotus Elise (1996) - page 5

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

  • Lotus Elise (1996) - page 6

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

  • Lotus Elise (1996) - page 7

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

  • Lotus Elise (1996) - page 8

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

  • Lotus Elise (1996) - page 9

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

  • Lotus Elise (1996) - page 10

    Pag e 8 200 0 / 0 3 ...

  • Lotus Elise (1996) - page 11

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

  • Lotus Elise (1996) - page 12

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

  • Lotus Elise (1996) - page 13

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

  • Lotus Elise (1996) - page 14

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

  • Lotus Elise (1996) - page 15

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

  • Lotus Elise (1996) - page 16

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

  • Lotus Elise (1996) - page 17

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

  • Lotus Elise (1996) - page 18

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

  • Lotus Elise (1996) - page 19

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

  • Lotus Elise (1996) - page 20

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

  • Lotus Elise (1996) - page 21

    Pag e 2 ...

  • Lotus Elise (1996) - page 22

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

  • Lotus Elise (1996) - page 23

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

  • Lotus Elise (1996) - page 24

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

  • Lotus Elise (1996) - page 25

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

  • Lotus Elise (1996) - page 26

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

  • Lotus Elise (1996) - page 27

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

  • Lotus Elise (1996) - page 28

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

  • Lotus Elise (1996) - page 29

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

  • Lotus Elise (1996) - page 30

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

  • Lotus Elise (1996) - page 31

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

  • Lotus Elise (1996) - page 32

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

  • Lotus Elise (1996) - page 33

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

  • Lotus Elise (1996) - page 34

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

  • Lotus Elise (1996) - page 35

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

  • Lotus Elise (1996) - page 36

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

  • Lotus Elise (1996) - page 37

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

  • Lotus Elise (1996) - page 38

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

  • Lotus Elise (1996) - page 39

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

  • Lotus Elise (1996) - page 40

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

  • Lotus Elise (1996) - page 41

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

  • Lotus Elise (1996) - page 42

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

  • Lotus Elise (1996) - page 43

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

  • Lotus Elise (1996) - page 44

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

  • Lotus Elise (1996) - page 45

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

  • Lotus Elise (1996) - page 46

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

  • Lotus Elise (1996) - page 47

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

  • Lotus Elise (1996) - page 48

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

  • Lotus Elise (1996) - page 49

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

  • Lotus Elise (1996) - page 50

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

  • Lotus Elise (1996) - page 51

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

  • Lotus Elise (1996) - page 52

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

  • Lotus Elise (1996) - page 53

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

  • Lotus Elise (1996) - page 54

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

  • Lotus Elise (1996) - page 55

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

  • Lotus Elise (1996) - page 56

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

  • Lotus Elise (1996) - page 57

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

  • Lotus Elise (1996) - page 58

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

  • Lotus Elise (1996) - page 59

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

  • Lotus Elise (1996) - page 60

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

  • Lotus Elise (1996) - page 61

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

  • Lotus Elise (1996) - page 62

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

  • Lotus Elise (1996) - page 63

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

  • Lotus Elise (1996) - page 64

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

  • Lotus Elise (1996) - page 65

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

  • Lotus Elise (1996) - page 66

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

  • Lotus Elise (1996) - page 67

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

  • Lotus Elise (1996) - page 68

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

  • Lotus Elise (1996) - page 69

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

  • Lotus Elise (1996) - page 70

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

  • Lotus Elise (1996) - page 71

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

  • Lotus Elise (1996) - page 72

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

  • Lotus Elise (1996) - page 73

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

  • Lotus Elise (1996) - page 74

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

  • Lotus Elise (1996) - page 75

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

  • Lotus Elise (1996) - page 76

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

  • Lotus Elise (1996) - page 77

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

  • Lotus Elise (1996) - page 78

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

  • Lotus Elise (1996) - page 79

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

  • Lotus Elise (1996) - page 80

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

  • Lotus Elise (1996) - page 81

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

  • Lotus Elise (1996) - page 82

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

  • Lotus Elise (1996) - page 83

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

  • Lotus Elise (1996) - page 84

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

  • Lotus Elise (1996) - page 85

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

  • Lotus Elise (1996) - page 86

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

  • Lotus Elise (1996) - page 87

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

  • Lotus Elise (1996) - page 88

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

  • Lotus Elise (1996) - page 89

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

  • Lotus Elise (1996) - page 90

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

  • Lotus Elise (1996) - page 91

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

  • Lotus Elise (1996) - page 92

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

  • Lotus Elise (1996) - page 93

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

  • Lotus Elise (1996) - page 94

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

  • Lotus Elise (1996) - page 95

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

  • Lotus Elise (1996) - page 96

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

  • Lotus Elise (1996) - page 97

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

  • Lotus Elise (1996) - page 98

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

  • Lotus Elise (1996) - page 99

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

  • Lotus Elise (1996) - page 100

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

  • Lotus Elise (1996) - page 101

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

  • Lotus Elise (1996) - page 102

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

  • Lotus Elise (1996) - page 103

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

  • Lotus Elise (1996) - page 104

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

  • Lotus Elise (1996) - page 105

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

  • Lotus Elise (1996) - page 106

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

  • Lotus Elise (1996) - page 107

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

  • Lotus Elise (1996) - page 108

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

  • Lotus Elise (1996) - page 109

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

  • Lotus Elise (1996) - page 110

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

  • Lotus Elise (1996) - page 111

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

  • Lotus Elise (1996) - page 112

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

  • Lotus Elise (1996) - page 113

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

  • Lotus Elise (1996) - page 114

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

  • Lotus Elise (1996) - page 115

    IN E DESCRIPTIO N AN D OPERATIO N ...

  • Lotus Elise (1996) - page 116

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

  • Lotus Elise (1996) - page 117

    IGIN E DESCRIPTIO N AN D OPERATIO N ...

  • Lotus Elise (1996) - page 118

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

  • Lotus Elise (1996) - page 119

    GIN E DESCRIPTIO N AN D OPERATIO N ...

  • Lotus Elise (1996) - page 120

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

  • Lotus Elise (1996) - page 121

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

  • Lotus Elise (1996) - page 122

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

  • Lotus Elise (1996) - page 123

    O N AN D OPERATIO N ...

  • Lotus Elise (1996) - page 124

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

  • Lotus Elise (1996) - page 125

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

  • Lotus Elise (1996) - page 126

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

  • Lotus Elise (1996) - page 127

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

  • Lotus Elise (1996) - page 128

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

  • Lotus Elise (1996) - page 129

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

  • Lotus Elise (1996) - page 130

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

  • Lotus Elise (1996) - page 131

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

  • Lotus Elise (1996) - page 132

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

  • Lotus Elise (1996) - page 133

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

  • Lotus Elise (1996) - page 134

    DESCRIPTIO N AN D OPERATIO N 111 ...

  • Lotus Elise (1996) - page 135

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

  • Lotus Elise (1996) - page 136

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

  • Lotus Elise (1996) - page 137

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

  • Lotus Elise (1996) - page 138

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

  • Lotus Elise (1996) - page 139

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

  • Lotus Elise (1996) - page 140

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

  • Lotus Elise (1996) - page 141

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

  • Lotus Elise (1996) - page 142

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

  • Lotus Elise (1996) - page 143

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

  • Lotus Elise (1996) - page 144

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

  • Lotus Elise (1996) - page 145

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

  • Lotus Elise (1996) - page 146

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

  • Lotus Elise (1996) - page 147

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

  • Lotus Elise (1996) - page 148

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

  • Lotus Elise (1996) - page 149

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

  • Lotus Elise (1996) - page 150

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

  • Lotus Elise (1996) - page 151

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

  • Lotus Elise (1996) - page 152

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

  • Lotus Elise (1996) - page 153

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

  • Lotus Elise (1996) - page 154

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

  • Lotus Elise (1996) - page 155

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

  • Lotus Elise (1996) - page 156

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

  • Lotus Elise (1996) - page 157

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

  • Lotus Elise (1996) - page 158

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

  • Lotus Elise (1996) - page 159

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

  • Lotus Elise (1996) - page 160

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

  • Lotus Elise (1996) - page 161

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

  • Lotus Elise (1996) - page 162

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

  • Lotus Elise (1996) - page 163

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

  • Lotus Elise (1996) - page 164

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

  • Lotus Elise (1996) - page 165

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

  • Lotus Elise (1996) - page 166

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

  • Lotus Elise (1996) - page 167

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

  • Lotus Elise (1996) - page 168

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

  • Lotus Elise (1996) - page 169

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

  • Lotus Elise (1996) - page 170

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

  • Lotus Elise (1996) - page 171

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

  • Lotus Elise (1996) - page 172

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

  • Lotus Elise (1996) - page 173

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

  • Lotus Elise (1996) - page 174

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

  • Lotus Elise (1996) - page 175

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

  • Lotus Elise (1996) - page 176

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

  • Lotus Elise (1996) - page 177

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

  • Lotus Elise (1996) - page 178

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

  • Lotus Elise (1996) - page 179

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

  • Lotus Elise (1996) - page 180

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

  • Lotus Elise (1996) - page 181

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

  • Lotus Elise (1996) - page 182

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

  • Lotus Elise (1996) - page 183

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

  • Lotus Elise (1996) - page 184

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

  • Lotus Elise (1996) - page 185

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

  • Lotus Elise (1996) - page 186

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

  • Lotus Elise (1996) - page 187

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

  • Lotus Elise (1996) - page 188

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

  • Lotus Elise (1996) - page 189

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

  • Lotus Elise (1996) - page 190

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

  • Lotus Elise (1996) - page 191

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

  • Lotus Elise (1996) - page 192

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

  • Lotus Elise (1996) - page 193

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

  • Lotus Elise (1996) - page 194

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

  • Lotus Elise (1996) - page 195

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

  • Lotus Elise (1996) - page 196

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

  • Lotus Elise (1996) - page 197

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

  • Lotus Elise (1996) - page 198

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

  • Lotus Elise (1996) - page 199

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

  • Lotus Elise (1996) - page 200

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

  • Lotus Elise (1996) - page 201

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

  • Lotus Elise (1996) - page 202

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

  • Lotus Elise (1996) - page 203

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

  • Lotus Elise (1996) - page 204

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

  • Lotus Elise (1996) - page 205

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

  • Lotus Elise (1996) - page 206

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

  • Lotus Elise (1996) - page 207

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

  • Lotus Elise (1996) - page 208

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

  • Lotus Elise (1996) - page 209

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

  • Lotus Elise (1996) - page 210

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

  • Lotus Elise (1996) - page 211

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

  • Lotus Elise (1996) - page 212

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

  • Lotus Elise (1996) - page 213

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

  • Lotus Elise (1996) - page 214

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

  • Lotus Elise (1996) - page 215

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

  • Lotus Elise (1996) - page 216

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

  • Lotus Elise (1996) - page 217

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

  • Lotus Elise (1996) - page 218

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

  • Lotus Elise (1996) - page 219

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

  • Lotus Elise (1996) - page 220

    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 ...

  • Lotus Elise (1996) - page 221

    ENGIN E 8 4 OVERHAU L ...

  • Lotus Elise (1996) - page 222

    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 ...

  • Lotus Elise (1996) - page 223

    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 ...

  • Lotus Elise (1996) - page 224

    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 , ...

  • Lotus Elise (1996) - page 225

    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 ...

  • Lotus Elise (1996) - page 226

    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 ...

  • Lotus Elise (1996) - page 227

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

  • Lotus Elise (1996) - page 228

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

  • Lotus Elise (1996) - page 229

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

  • Lotus Elise (1996) - page 230

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

  • Lotus Elise (1996) - page 231

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

  • Lotus Elise (1996) - page 232

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

  • Lotus Elise (1996) - page 233

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

  • Lotus Elise (1996) - page 234

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

  • Lotus Elise (1996) - page 235

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

  • Lotus Elise (1996) - page 236

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

  • Lotus Elise (1996) - page 237

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

  • Lotus Elise (1996) - page 238

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

  • Lotus Elise (1996) - page 239

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

  • Lotus Elise (1996) - page 240

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

  • Lotus Elise (1996) - page 241

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

  • Lotus Elise (1996) - page 242

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

  • Lotus Elise (1996) - page 243

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

  • Lotus Elise (1996) - page 244

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

  • Lotus Elise (1996) - page 245

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

  • Lotus Elise (1996) - page 246

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

  • Lotus Elise (1996) - page 247

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

  • Lotus Elise (1996) - page 248

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

  • Lotus Elise (1996) - page 249

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

  • Lotus Elise (1996) - page 250

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

  • Lotus Elise (1996) - page 251

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

  • Lotus Elise (1996) - page 252

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

  • Lotus Elise (1996) - page 253

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

  • Lotus Elise (1996) - page 254

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

  • Lotus Elise (1996) - page 255

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

  • Lotus Elise (1996) - page 256

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

  • Lotus Elise (1996) - page 257

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

  • Lotus Elise (1996) - page 258

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

  • Lotus Elise (1996) - page 259

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

  • Lotus Elise (1996) - page 260

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

  • Lotus Elise (1996) - page 261

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

  • Lotus Elise (1996) - page 262

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

  • Lotus Elise (1996) - page 263

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

  • Lotus Elise (1996) - page 264

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

  • Lotus Elise (1996) - page 265

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

  • Lotus Elise (1996) - page 266

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

  • Lotus Elise (1996) - page 267

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

  • Lotus Elise (1996) - page 268

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

  • Lotus Elise (1996) - page 269

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

  • Lotus Elise (1996) - page 270

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

  • Lotus Elise (1996) - page 271

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

  • Lotus Elise (1996) - page 272

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

  • Lotus Elise (1996) - page 273

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

  • Lotus Elise (1996) - page 274

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

  • Lotus Elise (1996) - page 275

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

  • Lotus Elise (1996) - page 276

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

  • Lotus Elise (1996) - page 277

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

  • Lotus Elise (1996) - page 278

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

  • Lotus Elise (1996) - page 279

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

  • Lotus Elise (1996) - page 280

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

  • Lotus Elise (1996) - page 281

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

  • Lotus Elise (1996) - page 282

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

  • Lotus Elise (1996) - page 283

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

  • Lotus Elise (1996) - page 284

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

  • Lotus Elise (1996) - page 285

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

  • Lotus Elise (1996) - page 286

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

  • Lotus Elise (1996) - page 287

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

  • Lotus Elise (1996) - page 288

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

  • Lotus Elise (1996) - page 289

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

  • Lotus Elise (1996) - page 290

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

  • Lotus Elise (1996) - page 291

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

  • Lotus Elise (1996) - page 292

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

  • Lotus Elise (1996) - page 293

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

  • Lotus Elise (1996) - page 294

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

  • Lotus Elise (1996) - page 295

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

  • Lotus Elise (1996) - page 296

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

  • Lotus Elise (1996) - page 297

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

  • Lotus Elise (1996) - page 298

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

  • Lotus Elise (1996) - page 299

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

  • Lotus Elise (1996) - page 300

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

  • Lotus Elise (1996) - page 301

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

  • Lotus Elise (1996) - page 302

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

  • Lotus Elise (1996) - page 303

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

  • Lotus Elise (1996) - page 304

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

  • Lotus Elise (1996) - page 305

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

  • Lotus Elise (1996) - page 306

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

  • Lotus Elise (1996) - page 307

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

  • Lotus Elise (1996) - page 308

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

  • Lotus Elise (1996) - page 309

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

  • Lotus Elise (1996) - page 310

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

  • Lotus Elise (1996) - page 311

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

  • Lotus Elise (1996) - page 312

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

  • Lotus Elise (1996) - page 313

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

  • Lotus Elise (1996) - page 314

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

  • Lotus Elise (1996) - page 315

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

  • Lotus Elise (1996) - page 316

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

  • Lotus Elise (1996) - page 317

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

  • Lotus Elise (1996) - page 318

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

  • Lotus Elise (1996) - page 319

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

  • Lotus Elise (1996) - page 320

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

  • Lotus Elise (1996) - page 321

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

  • Lotus Elise (1996) - page 322

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

  • Lotus Elise (1996) - page 323

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

  • Lotus Elise (1996) - page 324

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

  • Lotus Elise (1996) - page 325

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

  • Lotus Elise (1996) - page 326

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

  • Lotus Elise (1996) - page 327

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

  • Lotus Elise (1996) - page 328

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

  • Lotus Elise (1996) - page 329

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

  • Lotus Elise (1996) - page 330

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

  • Lotus Elise (1996) - page 331

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

  • Lotus Elise (1996) - page 332

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

  • Lotus Elise (1996) - page 333

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

  • Lotus Elise (1996) - page 334

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

  • Lotus Elise (1996) - page 335

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

  • Lotus Elise (1996) - page 336

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

  • Lotus Elise (1996) - page 337

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

  • Lotus Elise (1996) - page 338

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

  • Lotus Elise (1996) - page 339

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

  • Lotus Elise (1996) - page 340

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

  • Lotus Elise (1996) - page 341

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

  • Lotus Elise (1996) - page 342

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

  • Lotus Elise (1996) - page 343

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

  • Lotus Elise (1996) - page 344

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

  • Lotus Elise (1996) - page 345

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

  • Lotus Elise (1996) - page 346

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

  • Lotus Elise (1996) - page 347

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

  • Lotus Elise (1996) - page 348

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

  • Lotus Elise (1996) - page 349

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

  • Lotus Elise (1996) - page 350

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

  • Lotus Elise (1996) - page 351

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

  • Lotus Elise (1996) - page 352

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

  • Lotus Elise (1996) - page 353

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

  • Lotus Elise (1996) - page 354

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

  • Lotus Elise (1996) - page 355

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

  • Lotus Elise (1996) - page 356

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

  • Lotus Elise (1996) - page 357

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

  • Lotus Elise (1996) - page 358

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

  • Lotus Elise (1996) - page 359

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

  • Lotus Elise (1996) - page 360

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

  • Lotus Elise (1996) - page 361

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

  • Lotus Elise (1996) - page 362

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

  • Lotus Elise (1996) - page 363

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

  • Lotus Elise (1996) - page 364

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

  • Lotus Elise (1996) - page 365

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

  • Lotus Elise (1996) - page 366

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

  • Lotus Elise (1996) - page 367

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

  • Lotus Elise (1996) - page 368

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

  • Lotus Elise (1996) - page 369

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

  • Lotus Elise (1996) - page 370

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

  • Lotus Elise (1996) - page 371

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

  • Lotus Elise (1996) - page 372

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

  • Lotus Elise (1996) - page 373

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

  • Lotus Elise (1996) - page 374

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

  • Lotus Elise (1996) - page 375

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

  • Lotus Elise (1996) - page 376

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

  • Lotus Elise (1996) - page 377

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

  • Lotus Elise (1996) - page 378

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

  • Lotus Elise (1996) - page 379

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

  • Lotus Elise (1996) - page 380

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

  • Lotus Elise (1996) - page 381

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

  • Lotus Elise (1996) - page 382

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

  • Lotus Elise (1996) - page 383

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

  • Lotus Elise (1996) - page 384

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

  • Lotus Elise (1996) - page 385

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

  • Lotus Elise (1996) - page 386

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

  • Lotus Elise (1996) - page 387

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

  • Lotus Elise (1996) - page 388

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

  • Lotus Elise (1996) - page 389

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

  • Lotus Elise (1996) - page 390

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

  • Lotus Elise (1996) - page 391

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

  • Lotus Elise (1996) - page 392

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

  • Lotus Elise (1996) - page 393

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

  • Lotus Elise (1996) - page 394

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

  • Lotus Elise (1996) - page 395

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

  • Lotus Elise (1996) - page 396

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

  • Lotus Elise (1996) - page 397

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

  • Lotus Elise (1996) - page 398

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

  • Lotus Elise (1996) - page 399

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

  • Lotus Elise (1996) - page 400

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

  • Lotus Elise (1996) - page 401

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

  • Lotus Elise (1996) - page 402

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

  • Lotus Elise (1996) - page 403

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

  • Lotus Elise (1996) - page 404

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

  • Lotus Elise (1996) - page 405

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

  • Lotus Elise (1996) - page 406

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

  • Lotus Elise (1996) - page 407

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

  • Lotus Elise (1996) - page 408

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

  • Lotus Elise (1996) - page 409

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

  • Lotus Elise (1996) - page 410

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

  • Lotus Elise (1996) - page 411

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

  • Lotus Elise (1996) - page 412

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

  • Lotus Elise (1996) - page 413

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

  • Lotus Elise (1996) - page 414

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

  • Lotus Elise (1996) - page 415

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

  • Lotus Elise (1996) - page 416

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

  • Lotus Elise (1996) - page 417

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

  • Lotus Elise (1996) - page 418

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

  • Lotus Elise (1996) - page 419

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

  • Lotus Elise (1996) - page 420

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

  • Lotus Elise (1996) - page 421

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

  • Lotus Elise (1996) - page 422

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

  • Lotus Elise (1996) - page 423

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

  • Lotus Elise (1996) - page 424

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

  • Lotus Elise (1996) - page 425

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

  • Lotus Elise (1996) - page 426

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

  • Lotus Elise (1996) - page 427

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

  • Lotus Elise (1996) - page 428

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

  • Lotus Elise (1996) - page 429

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

  • Lotus Elise (1996) - page 430

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

  • Lotus Elise (1996) - page 431

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

  • Lotus Elise (1996) - page 432

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

  • Lotus Elise (1996) - page 433

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

  • Lotus Elise (1996) - page 434

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

  • Lotus Elise (1996) - page 435

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

  • Lotus Elise (1996) - page 436

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

  • Lotus Elise (1996) - page 437

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

  • Lotus Elise (1996) - page 438

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

  • Lotus Elise (1996) - page 439

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

  • Lotus Elise (1996) - page 440

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

  • Lotus Elise (1996) - page 441

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

  • Lotus Elise (1996) - page 442

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

  • Lotus Elise (1996) - page 443

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

  • Lotus Elise (1996) - page 444

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

  • Lotus Elise (1996) - page 445

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

  • Lotus Elise (1996) - page 446

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

  • Lotus Elise (1996) - page 447

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

  • Lotus Elise (1996) - page 448

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

  • Lotus Elise (1996) - page 449

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

  • Lotus Elise (1996) - page 450

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

  • Lotus Elise (1996) - page 451

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

  • Lotus Elise (1996) - page 452

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

  • Lotus Elise (1996) - page 453

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

  • Lotus Elise (1996) - page 454

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

  • Lotus Elise (1996) - page 455

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

  • Lotus Elise (1996) - page 456

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

  • Lotus Elise (1996) - page 457

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

  • Lotus Elise (1996) - page 458

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

  • Lotus Elise (1996) - page 459

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

  • Lotus Elise (1996) - page 460

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

  • Lotus Elise (1996) - page 461

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

  • Lotus Elise (1996) - page 462

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

  • Lotus Elise (1996) - page 463

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

  • Lotus Elise (1996) - page 464

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

  • Lotus Elise (1996) - page 465

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

  • Lotus Elise (1996) - page 466

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

  • Lotus Elise (1996) - page 467

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

  • Lotus Elise (1996) - page 468

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

  • Lotus Elise (1996) - page 469

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

  • Lotus Elise (1996) - page 470

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

  • Lotus Elise (1996) - page 471

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

  • Lotus Elise (1996) - page 472

    Pag e 2 199 8 / 0 2 ...

  • Lotus Elise (1996) - page 473

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

  • Lotus Elise (1996) - page 474

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

  • Lotus Elise (1996) - page 475

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

  • Lotus Elise (1996) - page 476

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

  • Lotus Elise (1996) - page 477

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

  • Lotus Elise (1996) - page 478

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

  • Lotus Elise (1996) - page 479

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

  • Lotus Elise (1996) - page 480

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

  • Lotus Elise (1996) - page 481

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

  • Lotus Elise (1996) - page 482

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

  • Lotus Elise (1996) - page 483

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

  • Lotus Elise (1996) - page 484

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

  • Lotus Elise (1996) - page 485

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

  • Lotus Elise (1996) - page 486

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

  • Lotus Elise (1996) - page 487

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

  • Lotus Elise (1996) - page 488

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

  • Lotus Elise (1996) - page 489

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

  • Lotus Elise (1996) - page 490

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

  • Lotus Elise (1996) - page 491

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

  • Lotus Elise (1996) - page 492

    Pag e 1 0 ...

  • Lotus Elise (1996) - page 493

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

  • Lotus Elise (1996) - page 494

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

  • Lotus Elise (1996) - page 495

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

  • Lotus Elise (1996) - page 496

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

  • Lotus Elise (1996) - page 497

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

  • Lotus Elise (1996) - page 498

    Pag e 1 6 ...

  • Lotus Elise (1996) - page 499

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

  • Lotus Elise (1996) - page 500

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

  • Lotus Elise (1996) - page 501

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

  • Lotus Elise (1996) - page 502

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

  • Lotus Elise (1996) - page 503

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

  • Lotus Elise (1996) - page 504

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

  • Lotus Elise (1996) - page 505

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

  • Lotus Elise (1996) - page 506

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

  • Lotus Elise (1996) - page 507

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

  • Lotus Elise (1996) - page 508

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

  • Lotus Elise (1996) - page 509

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

  • Lotus Elise (1996) - page 510

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

  • Lotus Elise (1996) - page 511

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

  • Lotus Elise (1996) - page 512

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

  • Lotus Elise (1996) - page 513

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

  • Lotus Elise (1996) - page 514

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

  • Lotus Elise (1996) - page 515

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

  • Lotus Elise (1996) - page 516

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

  • Lotus Elise (1996) - page 517

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

  • Lotus Elise (1996) - page 518

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

  • Lotus Elise (1996) - page 519

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

  • Lotus Elise (1996) - page 520

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

  • Lotus Elise (1996) - page 521

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

  • Lotus Elise (1996) - page 522

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

  • Lotus Elise (1996) - page 523

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

  • Lotus Elise (1996) - page 524

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

  • Lotus Elise (1996) - page 525

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

  • Lotus Elise (1996) - page 526

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

  • Lotus Elise (1996) - page 527

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

  • Lotus Elise (1996) - page 528

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

  • Lotus Elise (1996) - page 529

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

  • Lotus Elise (1996) - page 530

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

  • Lotus Elise (1996) - page 531

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

  • Lotus Elise (1996) - page 532

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

  • Lotus Elise (1996) - page 533

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

  • Lotus Elise (1996) - page 534

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

  • Lotus Elise (1996) - page 535

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

  • Lotus Elise (1996) - page 536

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

  • Lotus Elise (1996) - page 537

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

  • Lotus Elise (1996) - page 538

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

  • Lotus Elise (1996) - page 539

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

  • Lotus Elise (1996) - page 540

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

  • Lotus Elise (1996) - page 541

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

  • Lotus Elise (1996) - page 542

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

  • Lotus Elise (1996) - page 543

    Pag e 1 0 ...

  • Lotus Elise (1996) - page 544

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

  • Lotus Elise (1996) - page 545

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

  • Lotus Elise (1996) - page 546

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

  • Lotus Elise (1996) - page 547

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

  • Lotus Elise (1996) - page 548

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

  • Lotus Elise (1996) - page 549

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

  • Lotus Elise (1996) - page 550

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

  • Lotus Elise (1996) - page 551

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

  • Lotus Elise (1996) - page 552

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

  • Lotus Elise (1996) - page 553

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

  • Lotus Elise (1996) - page 554

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

  • Lotus Elise (1996) - page 555

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

  • Lotus Elise (1996) - page 556

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

  • Lotus Elise (1996) - page 557

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

  • Lotus Elise (1996) - page 558

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

  • Lotus Elise (1996) - page 559

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

  • Lotus Elise (1996) - page 560

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

  • Lotus Elise (1996) - page 561

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

  • Lotus Elise (1996) - page 562

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

  • Lotus Elise (1996) - page 563

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

  • Lotus Elise (1996) - page 564

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

  • Lotus Elise (1996) - page 565

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

  • Lotus Elise (1996) - page 566

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

  • Lotus Elise (1996) - page 567

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

  • Lotus Elise (1996) - page 568

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

  • Lotus Elise (1996) - page 569

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

  • Lotus Elise (1996) - page 570

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

  • Lotus Elise (1996) - page 571

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

  • Lotus Elise (1996) - page 572

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

  • Lotus Elise (1996) - page 573

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

  • Lotus Elise (1996) - page 574

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

  • Lotus Elise (1996) - page 575

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

  • Lotus Elise (1996) - page 576

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

  • Lotus Elise (1996) - page 577

    Pag e 4 4 ...

  • Lotus Elise (1996) - page 578

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

  • Lotus Elise (1996) - page 579

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

  • Lotus Elise (1996) - page 580

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

  • Lotus Elise (1996) - page 581

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

  • Lotus Elise (1996) - page 582

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

  • Lotus Elise (1996) - page 583

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

  • Lotus Elise (1996) - page 584

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

  • Lotus Elise (1996) - page 585

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

  • Lotus Elise (1996) - page 586

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

  • Lotus Elise (1996) - page 587

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

  • Lotus Elise (1996) - page 588

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

  • Lotus Elise (1996) - page 589

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

  • Lotus Elise (1996) - page 590

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

  • Lotus Elise (1996) - page 591

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

  • Lotus Elise (1996) - page 592

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

  • Lotus Elise (1996) - page 593

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

  • Lotus Elise (1996) - page 594

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

  • Lotus Elise (1996) - page 595

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

  • Lotus Elise (1996) - page 596

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

  • Lotus Elise (1996) - page 597

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

  • Lotus Elise (1996) - page 598

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

  • Lotus Elise (1996) - page 599

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

  • Lotus Elise (1996) - page 600

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

  • Lotus Elise (1996) - page 601

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

  • Lotus Elise (1996) - page 602

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

  • Lotus Elise (1996) - page 603

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

  • Lotus Elise (1996) - page 604

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

  • Lotus Elise (1996) - page 605

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

  • Lotus Elise (1996) - page 606

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

  • Lotus Elise (1996) - page 607

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

  • Lotus Elise (1996) - page 608

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

  • Lotus Elise (1996) - page 609

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

  • Lotus Elise (1996) - page 610

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

  • Lotus Elise (1996) - page 611

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

  • Lotus Elise (1996) - page 612

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

  • Lotus Elise (1996) - page 613

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

  • Lotus Elise (1996) - page 614

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

  • Lotus Elise (1996) - page 615

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

  • Lotus Elise (1996) - page 616

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

  • Lotus Elise (1996) - page 617

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

  • Lotus Elise (1996) - page 618

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

  • Lotus Elise (1996) - page 619

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

  • Lotus Elise (1996) - page 620

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

  • Lotus Elise (1996) - page 621

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

  • Lotus Elise (1996) - page 622

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

  • Lotus Elise (1996) - page 623

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

  • Lotus Elise (1996) - page 624

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

Manufacturer Lotus Category Car

Documents that we receive from a manufacturer of a Lotus Elise (1996) can be divided into several groups. They are, among others:
- Lotus technical drawings
- Elise (1996) manuals
- Lotus product data sheets
- information booklets
- or energy labels Lotus Elise (1996)
All of them are important, but the most important information from the point of view of use of the device are in the user manual Lotus Elise (1996).

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Lotus Elise (1996), service manual, brief instructions and user manuals Lotus Elise (1996). Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Lotus Elise (1996).

Similar manuals

A complete manual for the device Lotus Elise (1996), how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Lotus Elise (1996) by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Lotus Elise (1996).

A complete Lotus manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Lotus Elise (1996) - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Lotus Elise (1996), FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Lotus Elise (1996), that we can find in the current document
3. Tips how to use the basic functions of the device Lotus Elise (1996) - which should help us in our first steps of using Lotus Elise (1996)
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Lotus Elise (1996)
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Lotus Elise (1996) in a specific country, if it was not possible to solve the problem on our own.

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