Lotus - Elan - Workshop Manual - (2005)

Lotus Service Notes Introduction CONTENTS ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ ENGINE Section TDP TDQ Technical Data - Engine - Vehicle Chassis AH Bodycare & Repair BQ Body Fittings BR Front Suspension CI Rear Suspension DH Engine & Engine Management - Lotus supplement - Toyota 1ZZ/2ZZ engine repair manual * see separate manual B120T0327J - Toyota 2ZZ-GE engine supplement # see separate manual C120T0327J EH * Engine Management Transmission # EMP - Lotus supplement - Toyota C64 transmission repair manual ~ see separate manual D120T0327J - Toyota C56 transmission repair manual ^ see separate manual TBA FJ ~ ^ Wheels & Tyres GH Steering HG Brakes JJ Engine Cooling KH Fuel System - Except North America - North America LJ LK Electrics MP Maintenance & Lubrication OI Air Conditioning, Heating & Ventilation PL Clutch QH Passive Restraint (North America) WD Supplement - Exige Supercharged (S/C) Exige S/C Supplement - 2-Eleven 2-Eleven Page 1 Lotus Service Notes Introduction VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch area, viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside of the chassis sideframe alongside the driver's seat. The engine number is marked on a vertical patch at the right hand side of the rear face of the cylinder block, adjacent to the clutch housing. Both numbers should always be quoted with any vehicle enquiries, as Factory records are filed against V.I.N., and specification change points are identified by V.I.N. or engine number. The vehicle licence number should be considered irrelevant, since it may not accurately reflect vehicle age, and may also be changed during the car’s life. V.I.N. ON CHASSIS ohs119a V.I.N. LABEL ohs104 ENGINE NUMBER ohs133 The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC) and National Highway Traffic Safety Association (NHTSA) directives. For change point identification in Service Notes, Service Bulletins and Service Parts Lists, typically, only characters 10 (model year), and 14 to 17 (serial number) will be quoted. '2004 M.Y. onwards Manufacturer Identifier Code Vehicle Type 111 = Elise 123 = 2-Eleven Check Digit Assembly Plant H = Hethel B = Shah Alam S C C 1 2 3 5 9 11 4 Engine Type L = Motorsport N = 2ZZ s/c 255 P = 2ZZ n.a. V = 2ZZ s/c Y = 1ZZ * Track only. Not approved for road use Page 2 6 7 8 Restraint A = Active belts C = Dual S.I.R. + active belts 10 Model Year 4 = 2004 5 = 2005 6 = 2006 7 = 2007 8 = 2008 9 = 2009 A = 2010 12 Model 2 = 2-Eleven 3 = Elise 8 = Exige 13 14 15 16 17 Chassis/Body A = LHD Fed. C = RHD D = LHD F = U.K. SVA RHD G = U.K. SVA LHD H = Motorsport* J = Motorsport* L = LHD Fed. a.c. M = LHD Can. a.c. N = RHD a.c. P = LHD a.c. Serial Number Lotus Service Notes Introduction MODEL HISTORY MILESTONES Elise 111R Introduction: January 2004 VIN character 4 = P; Character 13 = 3; Serial number from 0970 Note that the serial number sequence is shared with other Elise variants. Changes from previous model include: Toyota powertrain with 1.8 litre VVTL-i engine and 6-speed transmission. Twin exhaust tailpipes exiting through centre of diffuser. Larger fuel tank with new pump. Revised chassis rail rear ends, new rear subframe, revised seat belt mounting frame backstays. Revised rear suspension wishbones, springs and dampers. ABS brake control with vacuum servo. Revised front bonnet grilles and access covers. 2004 Exige Introduction: March 2004 VIN character 4 = P; Character 13 = 8; Serial number from 1092 Note that the serial number sequence is shared with other Elise variants. Differences compared with Elise 111R include: Restyled front and rear clamshells with roof scoop, new tailgate panel and strut mounted rear aerofoil. Front body splitter panel. Re-styled road wheels, wider on the front, and Yokohama A048 tyres. 2005 M.Y. Elise for North America: May 2004 VIN character 10 = 5; Character 12 = L; Serial number from 0001 Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for those models later in the year. Differences compared with Elise 111R include: Driver and passenger airbags, pyrotechnic seat belt pretensioners; Re-styled fascia and dashboard structure; Front speakers moved onto top surface of fascia, stowage pockets incorporated into dashboard end panels, fixed windscreen demist vents. Engine start button in driver's side switch panel. Revised springs and dampers, Yokohama AD07 tyres. Side marker lamps on front and rear wheelarch lips. Revised fuel system with fuel filler flap. Lotus Sport Exige 240R: March 2005 Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the VIN coding. Differences compared to standard Exige include: 243 bhp engine upgrade using Eaton M62 supercharger with integral by-pass valve, air/air chargecooler and 5th fuel injector. Re-programmed ECU. Accusump. Stiffened springs & Ohlins adjustable dampers. Adjustable front anti-roll bar. Chassis rear brace kit. Forged 5-spoke widened roadwheels & Yokohama A048 tyres. Motorsport brake pads, braided hoses, yellow callipers, Castrol SRF brake fluid. Sport Yellow body colour with black wheels, or Sport Black body with silver wheels. Black interior with yellow inserts. 4-point harnesses, T45 roof hoop and backstays. 2006 M.Y. Introduction: September 2005 VIN character 10 = 6; Serial number restarts at 0001, common to all variants. Introduction of USA Exige and Canadian Elise. 5-speed Elise remains unchanged. Differences between 6-speed '06 Elise and '05 include; Electronic throttle control (using no mechanical cable). Optional Lotus Traction Control (LTC) or Limited Slip Differential (LSD) with LTC. Standard fit Yokohama AD07 tyres on non-USA cars. Optional forged wheels with new 6.0 in front size. LED rear lamp clusters incorporating reflectors (formerly separate), and commonised USA type CHMSL. ProBax seat foams. New body colours. USA & Canadian Elise; revised fuel tank and evap. loss system. Canadian Elise uses daytime running lights and clutch down start allow switch. USA Exige similar to non-USA, but with USA airbag interior. Sports Racer: October 2005 Special paint versions of '06 M.Y. 111R in either Ardent Red with triple Monaco White stripes, or Nightfall Blue with twin Monaco White stripes. Combined total of 199 units with unique build plate on sill. Forged wheels (6J on front), AD07 tyres, sport suspension, twin front oil coolers, LTC. Black leather interior with red or blue stitching, and red or blue 'Elise' embroidered into head restraints. Sports Racer decals. Page 3 Lotus Service Notes Introduction Exige Cup 190 & 240: January 2006 Limited number of competition oriented naturally aspirated (190) or supercharged (240) models produced as post registration official factory conversions of '06 Exige by the Lotus Sport workshops at Hethel for U.K. and certain overseas territories. Not identifiable from VIN coding. Differences compared to 240R (see above) include: Electronic throttle, high flow port injectors (no 5th). Cup 240 fitted with torque sensing LSD with LTC. Cup 190 uses friction plate LSD. Standard Exige wheels in 'Hi-power' silver. Race cars fitted with FIA 6-point roll cage, remote kill switch, extinguisher system. Standard body colours. Exige S: February 2006 VIN character 4 = V Factory built type approved supercharged Exige. Not USA. Differences to standard Exige include: 221 PS supercharged engine similar to 240R but using electronic throttle, smooth flow inlet adaptor, standard injectors without 5th injector, modified downpipe, optimised muffler with single oval tailpipe. Enlarged roof duct inlet for chargecooler. Body colour splitter, scoops and aerofoil. 'Exige S' decal on rear transom, 'S' on front quarter panels. USA Lotus Sport Elise: March 2006 Limited edition of 50. Saffron Yellow with twin Storm Titanium stripes. Saffron Yellow centre console. Yellow highlighted sports seats, 'carbon' door trim inserts. Harness bar, T45 seat belt mounting frame. Motorsport mats, stalks, winders and parking brake sleeve. Traction control, supersport suspension, black forged wheels, Yokohama A048s, braided brake hoses, silicone fluid, motorsport clutch. Lotus Sport decals and Union flags. Lotus Sport chassis plate. 2007 M.Y. & Elise S Introduction: June 2006 VIN character 10 = 7; Serial number restarts at 0001, common to all variants. VIN character 4 identifies engine type. Elise S = Y Differences between '07 Elise/Exige and '06 include: Elise 111R renamed Elise R; New sealed headlamp units; raised LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC ducting. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but fixed valve lift, plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within standard trims. Elise S also uses new C56 5-speed transmission and 6-spoke roadwheels sharing styling of standard '01 model wheels. USA Exige S: October 2006 The specification of the USA Exige S is that of the standard USA Exige and option packs, apart from the engine, which is as non-USA Exige S with the following exceptions: High flow port injectors, specific engine programming, 223 PS, 223 Nm. Carry-over features from the non-USA Exige S include exhaust downpipe and optimised muffler with single oval tailpipe, roof air intake funnel mouth. Exige S British GT Special Edition: November 2006 Celebrating Lotus Sport Cadena’s 2006 British GT3 Team Championship victory. Differences to standard Exige S include: Torsen LSD & Lotus Traction Control. Chassis rear brace kit. T45 roof hoop & stays. Braided brake hoses. Level 1 sports exhaust. Forged 7-bifurcated spoke silver wheels. Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills, Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow door trims and unique black/yellow trimmed seats. Optional a.c. Optional GT pack available as post registration official factory conversion by Lotus Sport workshops at Hethel for U.K. and certain overseas territories, includes: High flow injectors, different ECU & unique calibration for 243 bhp, Accusump, 2-way adjustable Ohlins dampers with uprated springs, 308mm front discs & 4-piston A.P. callipers, Pagid pads, Castrol SRF brake fluid. Page 4 Lotus Service Notes Introduction USA Low Speed Damage Mitigation: January 2007 From ‘07 USA VIN serial no. 1579. To meet USA safety legislation, modifications made to Elise/Exige: Front; armatures and foam inserts added between crash structure and clamshell. Rear; bumper panel housing foam pads either side of licence plate, narrower rear grilles, reinforced boot floor and diffuser support panel, stiffened diffuser. Some elements commonised for all markets. Lotus Sport Exige Cup 255: January 2007 Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding. Based on Exige Cup 240 (see above) with following differences: Power increase to 255 PS by; unique ECU calibration, enlarged chargecooler, extended roof duct, larger air cleaner and intake spout, uprated fuel pump. A.P. Racing 4 piston alloy front callipers, 308mm front discs. 2-Eleven Introduction: May 2007 VIN character 6/7/8 = 123; Character 13 = 2 Extreme, minimalist, track focussed Elise variant based on Exige Cup 255 powertrain componentry, but using new chargecooler arrangement. Produced in small numbers for U.K. and certain overseas territories. In U.K. only, SVA road going version available. All other territories only for track use, in LHD or RHD. New body with no doors or roof. Aeroscreen. Rear aerofoil in two versions. FIA compliant roll over bar. Chassis rear brace, unique front top wishbones and steering arms, optional Ohlins suspension. Accusump, twin front oil coolers. Standard LTC, optional variable LTC & Launch Control. Uprated clutch. Odyssey battery. Limited warranty for SVA cars. Extensive options list. USA Elise Limited Edition 'Type 72D' Limited edition of 50 cars to commemorate the 35th anniversary of Lotus' F1 1972 World Championship victory with the type 72D. Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black nosebadge, gold fuel filler cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspension. Black & gold seats and interior trim details with Limited Edition plaque. Scale model crash helmet. Page 5 Lotus Service Notes Introduction ENGINE BAY UNDERTRAY/DIFFUSER For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser panel. The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay clean. Do not run the car without the panels fitted. 3 screws to licence plate plinth 1 screw each side to grille panel b275b Diffuser panel Single screw each side to clamshell M8 button head (2) to subframe Page 6 5 screws undertray to diffuser M8 button head (2) to lower link brackets Undertray front edge slots into chassis 3 screws each side to tank bay panel Lotus Service Notes Introduction JACKING POINTS Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a 4-point lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using a 4-point lift, it is strongly recommended that for optimum stability and safety, positions B and D are used. A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift. B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use with 4-point lift in conjunction with (C). C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B). D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower wishbone rearmost mountings. Jacking at any other point may damage the chassis or body structure and/or jeopardise safety. ohs49sn Page 7