Lotus - Excel - Workshop Manual - (2004)

- t l-. (4 -J n q t LIJ () S fi (4 LIJ g -\ X l{J q l{J - t (4 t w a L o ! o I l:j lljI U LI|tllI tl : b 7 JI . h 3: U U!I Rd -) rr) N l*., v F -1 E !_ tI\ w 1-\ N ! z F lfr \v ; o C CU y f o) tJl r. : N O LIJ q ooa \r cs O t - a z A o 3 -:< *-: ro = d O t7 a ' - ^ n 3 5 .sl x o * r'T\ -7l .0o J - C - I.t 1,fi s ; + X ( L L J rI\ r) () a = d @ O O J(o O : O Y n;.o <> . f-t-, o C U F a-^ -c , o $ r - o O N t*, {-, J a tfr \v O O 0 :l F J I FORWARD This publication has been designed for use by Lotus Dealers, and may be updated periodically by the issuing of update packages to the dealer network. Lotus policy is one of continuous product improvement and the right is reserved to alter specifications at any time without prior notice. Whilst every care has been taken to ensure correctness of information, it is impossible to guarantee complete freedom from omissions and errors, or to accept liability arising from such errors or omissions, but nothing herein contained shall affect your statutory rights. USE OF THE PARTS LIST This parts list covers the Elise range, 2001 model year onwards. The manual is arranged in function groups, as defined by the Contents page, and may sometimes use several versions of the same function group to accommodate model variations – take care to establish the full vehicle specification in order to properly identify the applicable parts list section. PART NUMBERS Part numbers used in this publication are in the format as follows: Modification Identifier A Functional Group 111 Vehicle/Engine Type Number of first Usage B Supply Route (Internal Use) 1234 F Part Serial Number Modification Identifier: This letter identifies a version or modification of the part. Part numbers with different prefix letters may or may not be interchangeable – refer to the remarks column. Vehicle/Engine Type Number: The type number indicates either the model or engine type on which the part was first used. 026, 036, 045, 500…Elan 076…Eclat S1 084…Eclat S2 111…Elise 050…Elan+2 079…Esprit S1/S2/S2.2 085…Esprit S3 340…340R 046, 054, 065, 074…Europa 082…Esprit Turbo 089…Excel 117…Elise 2001 MY 075…Elite S1 083…Elite S2 100…Elan 1990 120....Elise European with Toyota Power-Train 121…Elise USA ’05 MY 122…European Exige ’04 MY 123…USA Exige ’06 MY Functional Group: A single letter indicating the functional area of the parts first use A = Chassis E = Engine J = Brakes P = Heater & AC B = Body F = Transmission K = Cooling Q = Clutch C = Front Suspension G = Wheels & Tires L = Fuel System R = Final Drive D = Rear Suspension H = Steering M = Electrics S = Exhaust U = Hard Trim V = Soft Trim W = Standard Fixings VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The vehicle identification number (VIN) is stamped on the chassis in the right hand front wheelarch area, viewable with the front wheels turned to full right lock, and is also printed on a label stuck to 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 enquires, as Factory records are filed against VIN, and specification change points are identified by VIN or engine number. The vehicle license number should be considered irrelevant, since it may not accurately reflect the vehicle age, and may also be changed during the cars life. The VIN comprises 17 characters, coded in accordance with European Economic Community (EEC) directives. For change point identification in Service Notes and Service Parts Lists, characters 10 (model year) and 15-17, or 14-17 (serial number) will be quoted. Assembly Manufacturer Identifier Code S C C 1 2 3 Vehicle Type 111= Elise 4 Engine Type P= 1.8 VVTL - i 5 6 7 Plant H= Hethel B= Shah Alam Check Digit 8 Restraint A = Active belts C = Dual S.I.R & Active belts 9 10 Model Year 4 = 2004 5 = 2005 6 = 2006 7 = 2007 11 12 13 Chassis/Body A = LHD Fed. C = RHD D = LHD L = LHD Fed. a.c N = RHD ac P = LHD ac Model 3 = Elise 8 = Exige 14 15 16 17 Serial Number -J tlJ a q " i U tll ) U €g ?;gu**E{ ?llgg E$iFiff e=gggtanEEaEI x,$Es$E;;i; flfi;E= *g*EEEct = i s : : g €-;lg* r e €; r F* ,r * u i ; ! i EE ilE r;*;gee s 5gE;E € ; ; IH r ,*EEE;gtt; s 5 E : sf *€f i:=;;frp*;it i Er: ? Er;P€€ r ; E f i z E E E=d= t q E €TEFfle[gE E+fiEFu Hritraalt;;itfir*iEtfi f AE-gl?! tl ;gs E gl H==E"*;EFFe H=="sa #=zQ*i*ui 10.00 Body 13.00 Seats & Seat Belts 10.01 10.01x 10.02a 10.04 10.09a 10.11 10.11x 10.13a 10.15 10.17 10.20 10.23x 10.25 10.31 Body: Front & Rear Clamshells & Fixings Body: Front & Rear Clamshells & Fixings, Exige Body: Sill Panels, Windscreen Frame & Rear Bulkhead Crash Structures Front Services Access Panels Engine Cover Lid & Latch Mechanism Tailgate & Release Mechanism, Exige Engine Compartment Finisher Panels Door Shells, Beams, Hinges Door Latch Mechanism Rear Window Shroud & Fixings Spoilers & Aerofoils, Exige Undertray & Diffuser Towing Strut/ Hook 13.01 13.02 13.27 Seat Runners Seat Assemblies Seat Belts 14.00 Pedal Box & Fascia 14.01 14.01a 14.05 14.05b 14.10 Pedal Box, Pedals, Throttle Cable Pedal Box, Pedals, Electronic Throttle Control Fascia Structure & Supporting Hardware Fascia Structure & Supporting Hardware, USA/Canada Instrument Cowling 15.00 Interior Trim 11.00 Glazing and Seals 11.01 11.02 Windscreen, Door Glass, Seals & Weather Strips Door Window Lift Mechanism 12.00 Exterior Fittings 15.05 15.11 15.13 15.18 15.19 15.24 15.30 Interior Driving Mirror & Sunvisors Interior Trim & Stowage Provision Front Door Trims Interior Trim, Chassis Trim Panels Centre Tunnel Trim, Gear Lever Gaiters/Shrouds Luggage Compartment Carpet Carpeting & Mats 12.01 12.02 12.03 12.04 12.04x 12.05 12.05x 12.07 12.09 Wheelarch Liners Soft Top Roof, Cant Rails, Roof Bows Grilles and Louvres Hard Top Roof, Seals and Fittings Roof Panel, Seals & Fixings, Exige Decals, Badges & Protective Film Decals, Badges & Protective Film, Exige Licence Plate Mountings Exterior Driving Mirrors 16.00 Sound Insulation 16.01 Passenger Compartment Sound Insulation 17.00 Electrical 17.01 17.03 17.05 17.06 17.06b 17.07 Harnesses, Leads Horn, Inertia Switch, Fuses & Relays Interior Switches, Auxiliary Power Socket Engine Management & Sensors SIR: Inflator Modules, DERM & Sensors Instruments, Tell Tales, & Displays Date: 06-Sep-05 Function Code List: Page 1 of 3 17.11 17.13 17.17 17.21 17.27 17.31 17.33 Exterior Lamps, Except Headlamps Headlamps Interior Lamps Windscreen Wiper Motor, Wipers & Washers In Car Entertainment Battery, Clamps, & Cables Security Alarm System 32.05 Upper Column, Wheel, Steering Lock 33.00 Brakes 33.01 33.03 33.05 Brake Discs & Calipers Master Cylinder, Servo, ABS Controller, Pipes & Hoses Parking Brake Mechanism 34.00 Wheels & Tyres 18.00 Heating, Ventilation, Air Conditioning 34.01 Wheels, Tyres & Valves 18.01 18.03 18.05 18.07a 18.09a 18.12 18.13 18.14 Heater/ Air Conditioning Assemblies, Housings AC Components, Pipes, Hoses Heater, Pipes, Hoses AC/Heater Interior Blower Motor AC/Heater Driver Operated Controls AC/Heater Air Distribution Plenum Air Trunking, Ducts & Ventilators AC Air Recirculation System 40.00 Engine 19.00 Labels 19.01 19.03 Labels,Certificates, Literature etc. Owner's Handbooks & Service Notes Manuals 30.00 Chassis 30.01 30.02 Chassis, Subframe Seat Belt Mounting Frame, Stays 31.00 Suspension 31.01 31.03 Front Suspension, Incl. Hubs Rear Suspension, Incl. Hubs 40.00 40.01 40.01a 40.02 40.02a 40.03 40.05 40.07 40.08 40.09 40.11 40.13 40.15 40.17 40.19 40.21 40.23 Engine Assemblies Engine Block, Oil Pick-up Engine Mounts Gaskets & Sealants, Top Overhaul Set Gaskets & Sealants, Bottom Overhaul Set Sump Assembly Cylinder Head , Valves, Springs Camshafts, Tappets, Cam Cover Camshaft Drive Chain & Sprockets Pistons, Con-rods, Liners Crankshaft, Bearings, Flywheel Water Pump Assembly, Thermostat Lubrication System Ignition System, Spark plugs & Plug Top Coils Alternator and Starter Motor Exhaust Manifold AC Compressor 32.00 Steering 41.00 Belts and Pulleys 32.01 Rack & Pinion, & Lower Column 41.03 Auxiliary Drive Belts & Pulleys Date: 06-Sep-05 Function Code List: Page 2 of 3 42.00 Induction Systems 42.01 42.04 42.05 42.07 Airboxes, Trunking & Air Filters Throttle Body, Mechanism & IAC Valve Fuel Injection System Inlet Manifolds, Plenum & Gaskets 44.00 Fuel System 44.01 44.01d 44.03 44.05 44.05c Fuel Tanks, Filler Fuel Tanks, Filler, USA/Canada Fuel Pump; Filter, Pipes Charcoal Canister & Evaporative Loss System. Charcoal Canister & Evap. Loss System, USA/Canada 45.00 Exhaust 45.01 45.05 Exhaust System Heatshields 46.00 Cooling 46.01 46.03 Engine Cooling System & Fan Oil Cooler & Pipes 47.00 Transmission 47.01 47.03 47.05 47.06 47.07 47.11 47.15 Clutch & Release Mechanism Transmission Assembly Gearchange Mechanism, External Gear Selector Mechanism, Internal Gears, Shafts & Bearings Final Drive & Bearings Driveshafts & Seals 60.00 Special tools 60.01 Tool Kit Date: 06-Sep-05 Function Code List: Page 3 of 3 60.01a 60.02 Diagnostic Equipment Special Tools 80.00 Bulk Items 80.20a Touch-in Paint Pencil Range August 2005 Attention Parts Manager Elise 111R/Elise North America/Exige Service Parts List A120T0325J - Update package 2005/02 Dear Sir/Madam, Please find the enclosed update package 2005/02 for the Elise111R/Elise North America/Exige Service Parts List A120T0325J. This covers mainly ‘06 Model Year changes, the introduction of Exige for the USA, plus Elise/Exige for Canada. This should be collated into your copy as follows: Discard (text and illus.) Insert Introduction & Function Code List, A3 page. Introduction & Function Code List, A3 page, (stamped ‘2005/02’). 10.01x, 10.04, 10.09a, 10.11x, 10.25, all pages. 10.01x, 10.04, 10.09a, 10.11x, 10.25, all pages, (stamped ‘2005/02’). 11.02, pages 2 & 3. 11.02, pages 2 & 3, (stamped ‘2005/02’). 12.01, pages 1 & 2, 12.03, page 2, 12.04, page 2. 12.05, 12.05x, all pages. 12.01, pages 1 & 2, 12.03, page 2, 12.04, page 2. 12.05, 12.05x, all pages, (stamped ‘2005/02’). 13.01, 13.02, all pages. 13.01, 13.02, all pages, (stamped ‘2005/02’). 14.01, page 3. 14.01a, all pages, (stamped ‘2005/02’). 15.05, all pages. 15.05, all pages, (stamped ‘2005/02’). 17.01, page 1, 17.03, pages 1 & 2, 17.05, all pages, 17.06, page1, 17.07, page 1, 17.11, all pages. 17.01, page 1, 17.03, pages 1 & 2, 17.05, all pages, 17.06, pages 1 & 2, 17.07, page 1, 17.11, all pages, (stamped ‘2005/02’). 18.03, pages 1 to 3. 18.03, pages 1 & 2, (stamped ‘2005/02’). 30.02, page 1 30.02, page 1, (stamped ‘2005/02’) 31.01, pages 1 to 4, 31.03, all pages. 31.01, pages 1 to 4, 31.03, all pages, (stamped ‘2005/02’). 32.01, page 1. 32.01, page 1, (stamped ‘2005/02’). 40.01, page 1, 40.01a, pages 1 & 2, 40.03, page 1 40.05, page 1, 40.11, page 1. 40.01, page 1, 40.01a, pages 1 & 2, 40.03, page 1, 40.05, page1, 40.11, page 1, (stamped ‘2005/02’). 44.01d, 44.03, pages 1 & 2, 44.05, 44.05c, all pages. 44.01d, 44.03, pages 1 & 2, 44.05, 44.05c, all pages, (stamped ‘2005/02’). 45.05, all pages. 45.05, all pages, (stamped ‘2005/02’). 46.03, pages 1 & 2. 46.03, pages 1 & 2, (stamped ‘2005/02’). 47.05, all pages, 47.06, page 2, 47.11, pages 1 to 3. 47.05, all pages, 47.06, page 2, 47.11, pages 1 to 3, (stamped ‘2005/02’). Please take time to correctly update this parts list, and ensure that all parts dept. personnel are made aware of the new content. Any copies of the parts list held in dealer stock should be updated by ordering under Part No. A120T0325/05/02. In the interests of both Lotus Cars and the dealer network, please take all reasonable precautions to protect Lotus copyright and discourage illegal copying and electronic conversion. Yours faithfully John Hostler - Illustrator/Parts List Controller A120uppl0502 co -\ ^ R \ \'Iq)) \ l s i - l ,:ffi i{lm- I ./- 6 d i T r 7- W N--+ tll tll J-- E I1l Service Parts List Function Code 10.01 Body: Front & Rear Clamshells & Fixings Dep Part Description 01 Front Clamshell 01a Front Clamshell, federal 02 Rear Clamshell 02a Rear Clamshell, federal 03 Remarks Option Part Number Qty A120B0010J R/B C120B0010J 1 USA/Canada A121B0002K 1 D120B0016J R/B F120B0016J 1 USA/Can. C121B0008K R/B E121B0008K 1 Door Hinge Cover Panel, RH A117B0220K 1 04 Door Hinge Cover Panel, LH A117B0219K 1 05 Screw, M8 x 25, S/S, button hd. A111W7175F 6 06 Washer, flat, S/S, M8 x 21 x 1.6 A111W4176F 8 07 Bracket, centre front clamshell C117B0193F 1 08 Screw, M6 x 16, hex. hd. A075W1028Z 19 08a Screw, M6 x 12, hex. hd. A075W1027Z 3 09 Washer, flat, M6 x 18 x 1 B082W4018F 22 10 Spirenut, M6 B100W6372F 3 11 Nut, M6 A075W3020Z 2 12 Washer, spring, M6 A075W4035F 2 13 Spigot, outer fixing, front access panels A117B0334F 2 14 Shouldered Nut, outer fixing, front access panels A117B0335F 2 15 Locknut, M10, height adjuster fix. A075W3024Z 4 Apertures for side marker lamps Apertures for side marker lamps Part of clamshell assy. Rear clam. to sill panel 2 RH, 1 LH Function Code: 10.01, Page: 1 Function Code 10.01 Body: Front & Rear Clamshells & Fixings Dep Part Description 16 Washer, flat, M10 x 24 x 1.5, spigot to clam. 17 Bracket, front clamshell 18 Remarks Part Number Qty A075W4023F 2 C117B0163F 2 Shim, boot floor to subframe, 1mm A116B0423K As req. 18a Shim, boot floor to subframe, 2mm A116B0424K As req. 19 Shim, front clamshell alignment, 0.5mm A116B0460K As req. 19a Shim, front clamshell alignment, 1.0mm A116B0461K As req. 20 Drain Cover, rear A117B0660K 1 21 Grommet, drain tube A036B6150Z 1 22 Drain Tube, 4mm A116M0040V 0.5M 23 Cable tie, tube retention A075W6038Z 1 24 Base, cable tie A117W6729F 1 25 Gutter Extension Panel, RHD A117B0703K 1 25a Gutter Extension Panel, LHD A117B0704K 1 26 Foam Strip, self adhesive A036B6221V 0.28M 27 Clip, extension panel to radiator A117B6003F 2 28 Bracket, front liner/access panel mounting B120B0088F 2 29 Pop Rivet, domed, black, bracket to clamshell A082W6512F 4 30 Buffer, self adhesive, clamshell to shroud Not illustrated A111J6027F 2 31 Pad, front clamshell mounting to rad. housing Not illustrated A117U0163F 2 32 Foam Infill, clamshell spine front Not illustrated, bonded to clam. A117B0502F 1 Part of clamshell assy. Option Function Code: 10.01, Page: 2 € F / \ ,c@sFil- { lnLT-g ss3 r t._ u-ttt\ \ ,-"$\r ,n:ffi)rw rn F (\ SS* (v) \ \ (:) o) tlj tl KI |,ilE Service Parts List Function Code 10.01x Body: Front & Rear Clamshells & Fixings, Exige Dep Part Description 01 Remarks Option Part Number Qty Front Clamshell Primed, C122B0007K R/B D122B0007K 1 01a Front Clamshell, federal Primed, USA/Canada A123B0014J 1 02 Rear Clamshell Primed, A122B0032K R/B C122B0032K 1 02a Rear Clamshell, federal Primed, USA/Canada A123B0018J 1 03 Door Hinge Cover Panel, RH Primed, A122B0018K R/B C122B0018K 1 04 Door Hinge Cover Panel, LH Primed, A122B0017K R/B C122B0017K 1 05 Bracket, front clamshell supporting A122B0012F 1 06 Bracket, rear clamshell to diffuser, RH A122B0132F 1 07 Bracket, rear clamshell to diffuser, LH A122B0133F 1 08 Duct Panel, side intake, RH Primed A122B0062K 1 09 Duct Panel, side intake, LH Primed A122B0061K 1 10 Bracket, side duct to sill A122B0202F 2 11 Spirenut, M5, side duct fixing to bracket & clamshell A117W6697F 6 12 Screw, M5 x 20, skt. button hd., side duct panel fix. A082W7173F 6 13 Escutcheon, screw to panel A340B0123F 6 14 Grille, front intake, centre, driving lamps Bonded inside clamshell, with finisher Euro, B122B0003F R/B D122B0003F 1 14a Grille, front intake, centre, without driving lamps Bonded inside clamshell, with finisher USA/Canada A122B0258F 1 Function Code: 10.01x, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 10.01x Body: Front & Rear Clamshells & Fixings, Exige Dep Part Description Remarks 15 Grille, front intake, RH 16 Option Part Number Qty Bonded inside clamshell A122B0004F 1 Grille, front intake, LH Bonded inside clamshell A122B0005F 1 17 Grille, front exit, RH Bonded inside clamshell A122B0002F 1 18 Grille, front exit, LH Bonded inside clamshell A122B0129F 1 19 Grille, exit, hinge cover panel, RH Bonded inside panel A122B0134F 1 20 Grille, exit, hinge cover panel, LH Bonded inside panel A122B0135F 1 21 Grille, side intake, RH Bonded to duct panel A122B0058F 1 22 Grille, side intake, LH Bonded to duct panel A122B0057F 1 23 Nut, M6, bracket to wiper bracket A075W3020Z 2 24 Washer, spring, M6, bracket to wiper bracket A075W4035Z 2 25 Screw, M8 x 25, S/S, button hd. clam fix. A111W7175F 6 26 Washer, flat, S/S, M8 x 21 x 1.6, clam fix. A111W4176F 6 27 Shim, clamshell alignment, 0.5mm A116B0460K As req. 27a Shim, clamshell alignment, 1.0mm A116B0461K As req. 28 Screw, M6 x 16, hex. hd., clamshell fix. A075W1028Z 19 28a Screw, M6 x 12, hex. hd., clamshell to sill A075W1027Z 3 29 Washer, flat, M6 x 18 x 1, clamshell fix. B082W4018F 22 30 Spirenut, M6, clamshell to front undertray B100W6372F 3 31 Bracket, rear clamshell to bulkhead B117B0091F 2 32 Screw, M5 x 10, flg. button hd.,., bracket to clamshell A117B0310H 4 33 Screw, M6 x 25, cap hd., bracket to bulkhead A111W7170F 2 2 RH, 1 LH Function Code: 10.01x, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 10.01x Body: Front & Rear Clamshells & Fixings, Exige Dep Part Description 34 Remarks Option Part Number Qty Washer, flat, M6 x 18 x 1, bracket to bulkhead B082W4018F 2 35 Spacer Washer, neoprene, bracket to bulkhead A111U6055F 4 36 Pop Rivet, bracket to sill panel A075W6087Z 6 37 Screw, M6, bracket to clamshell A100W5137F 4 38 Washer, flat, M6 x 18 x 1, bracket to clamshell B082W4018F 4 39 Shim, boot floor to subframe, 1mm A116B0423K As req. 39a Shim, boot floor to subframe, 2mm A116B0424K As req. 40 Cover, side grille pocket, LH Not illustrated, fixed to sill A122B0145K R/B C122B0145K 1 40a Cover, side grille pocket, RH Not illustrated, fixed to sill A122B0144K R/B C122B0144K 1 40b Screw, No.6 x 0.5", flg. hd. S/S black, cover to sill Not illustrated A089W5138F 4 40c Spirenut, No.8, cover to sill Not illustrated A075W6016Z 4 41 Edge Finisher, engine bay gutter Not illustrated A117B6010V 2.45M Function Code: 10.01x, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 19 18 20 1 11 9 10 7 2 9 10 16 4 See 10.04 3 15 7 13 14 8 18 12 6 21 9 10 16 9 17 10 5 10.02a Function Code 10.02a Body: Sill Panels, Windscreen Frame & Rear Bulkhead Dep Part Description 01 Remarks Option Part Number Qty Windscreen Frame Assembly Painted A116B0148K 1 02 Gutter, windscreen frame Elise B117B0153F 1 02a Gutter, windscreen frame Exige A122B0014F 1 03 Baffle Panel/FLV Plenum Assembly A120B0117F 1 04 Sill Panel, RH Elise A120B0050K 1 04a Sill Panel, RH Exige A122B0210K 1 05 Sill Panel, LH Elise A120B0051K 1 05a Sill Panel, LH Exige A122B0211K 1 06 Rear Bulkhead B120B0052F R/B C120B0052F 1 07 Edge Finisher, 'B' post, smooth A117U0462F 2 08 Edge Finisher, side intake, smooth A117U0463F 2 09 Captive Nut, M8, big hd. A111W6592F 18 10 Blanking Grommet, 12.5mm A100B6163F 1 11 Finisher Panel, front sill recess, RH B117U0168F 1 12 Finisher Panel, front sill recess, LH B117U0169F 1 13 Plastic Fastener, panel fix. A100W6479F 4 14 Pad, hole blanking, upper hinge fixings A117U0258F 2 15 Foam Strip, 300mm, baffle panel to screen frame Cut to fit, see Service Notes, section BO A082U6065V 2 16 Bracket, sill rear to chassis Bonded to chassis A120B0053F 2 17 Pop Rivet, bracket to sill A111W6613F 4 Function Code: 10.02a, Page: 1 Function Code 10.02a Body: Sill Panels, Windscreen Frame & Rear Bulkhead Dep Part Description Remarks Option Part Number Qty 18 Blanking Grommet, 38mm, sills front Unused oil hose holes Non oil cooler cars A116W6730F 2 19 Blanking Grommet, 30mm, RH sill front Unused AC pipe hole Heater cars A079U6033F 1 20 Blanking Grommet, 19mm, RH sill front Unused AC pipe hole Heater cars A116W6714F 1 21 Blanking Grommet, 40mm, door aperture front Unused door harness hole Non CDL cars A116W6730F 2 22 NVH Foam, sill front Not illustrated Heater cars C120B0074F 2 Function Code: 10.02a, Page: 2 1 10 14 9 15 7 12 3 13 11 8 2 4 5 6 10.04 Service Parts List Function Code 10.04 Crash Structures Dep Part Description 01 Remarks Option Part Number Qty Front Crash Structure Assembly A120B0094J 1 02 Panel, front undershield B117B0237F 1 02a Panel, front undershield, adjustable A/R bar A120B0152F 1 03 Spirenut, M6, undershield fix B100W6372F 6 04 Screw, M6 x 25, pozi., undershield fix A075W5089Z 9 05 Washer, spring, M6, undershield fix A075W4035Z 9 07 Alloy Plate. LH A111B0531F 1 07a Alloy Plate, RH A111B0530F 1 08 Pop Rivet, plate fix. A085W6259F 6 09 Washer, flat, 3/16" x 1/2", plate to crash structure A075W4000Z 4 10 Side Impact Foam, LH A120B0063F 1 11 Side Impact Foam, RH A120B0062F 1 12 Bracket, foams to chassis A117B0556F 2 13 Pop Rivet, brackets to chassis A117W6734F 8 14 Grille, leaf screen A117B0466F 2 15 Edging Strip, hose protection A111U6034F 0.3m 16 Betaseal 1701, crash structure to chassis A082B6281F 300mm Supersport option Bonded to crash structure Not illustrated Function Code: 10.04, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 bbff tl| tll Je lrld vl- Service Parts List Function Code 10.09a Front Services Access Panels Dep Part Description 01 Front Access Panel, RH 01a Front Access Panel, RH, primed 02 Front Access Panel, LH 02a Front Access Panel, LH, primed 03 Remarks Option Part Number Qty Elise B120B0042J 1 Exige A122B0028K R/B B122B0028K 1 Elise B120B0043J 1 Exige A122B0027K R/B B122B0027K 1 Grille, front access panel, RH A120B0036F 1 04 Grille, front access panel, LH A120B0037F 1 05 Screw, M5 x 20, button. skt. hd., panel fix. 6 off for Exige A082W7173F 2 06 Escutcheon, screw to panel 6 off for Exige B340B0123F 2 07 Washer, retaining, screw to panel 6 for off Exige A340W4183F 2 08 Screw, M5 x 16, button hd., S/S, grille to shroud/support A116W5281F 4 09 Washer, flat, M5 x 19 x 1.4 S/S, grille to shroud/support B075W4009Z 4 10 Spirenut, M5, grille to shroud/support A117W6697F 4 11 Support, grille outer, LH A120B0107F 1 11a Support, grille outer, RH A120B0106F 1 12 Screw, ejot, support to clamshell A117F6001F 2 13 Washer, flat, M5 x 19 x 1.4, support to clamshell B075W4009Z 2 14 Locator Pin, access panel to clamshell spine B120B0108F 4 Not illustrated Not illustrated Also Exige access panels 6 off for Exige Bonded to panel Function Code: 10.09a, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 40 21 2 35 3 36 34 33 37 6 32 4 39 5 38 1 22 24 13 23 45 20 12 8 19 11 28 18 41 17 7 42 43 10 9 29 27 25 16 26 14 15 10.11 30 44 31 Function Code 10.11 Engine Cover Lid & Latch Mechanism Dep Part Description 01 Remarks Part Number Qty Engine Cover Lid A120B0061K 1 02 Grille, outlet, RH rear C117B0218F 1 03 Grille, outlet, LH rear C117B0217F 1 04 Grille, outlet, RH front D117B0130F 1 05 Grille, outlet, LH front E117B0129F 1 06 Pop Rivet, plastic, rear grilles to lid A082W6528F 6 07 Hinge assembly C117B6002F 2 08 Stud Plate, hinge retention A117B0236F 2 09 Nyloc Nut, M6, hinge to stud plate A907E6285F 4 10 Washer, flat, M6 x 25 B075W4017Z 4 11 Screw, M6 x 16, hex. hd., hinge to lid A075W1028F 4 12 Washer, flat, M6 x 15 x 3 A075W4014Z 4 13 Washer, spacer, M8 x 20 x 2.5 A079W4019F 8 14 Striker Pin/Lift Assembly, engine cover lid C120B0007F 1 15 Screw, M6 x 16, hex.hd., bracket to bulkhead A075W1028Z 3 16 Washer, flat, M6 x 20 x 2.5, bracket to bulkhead B082W4016F 3 17 Striker Pin A117B0223F 1 18 Washer, flat, M10 x 20.5 x 1.8 A075W4024Z 1 19 Washer, flat, M6 x 12.1 x 1.4 A075W4013Z 1 20 Nyloc Nut, M6, pin to bracket A907E6285F 1 21 Weatherseal, luggage compartment gutter A117U6001V 1.92M Incl. heatshield, see 45.05 Option Function Code: 10.11, Page: 1 Function Code 10.11 Engine Cover Lid & Latch Mechanism Dep Part Description 22 Remarks Option Part Number Qty Bracket, latch retention C120B0020F 1 23 Nyloc Nut, M6, bracket to lid A907E6285F 4 24 Washer, flat, M6 x 12.1 x 1.4, bracket to lid A075W4013Z 4 25 Latch Assembly A120B6002F 1 26 Screw, M6 x 35, csk. skt. hd., latch to bracket Black finish A079W7004F 2 27 Washer, flat, M6 x 25 x 1.4, S/S Black finish A082W4131F 2 28 Lock Barrel P/O vehicle lock set, see 10.17 B117H0001F 1 29 Clip, barrel retention A117B6009F 1 30 Cover, latch assembly A120U0003F 1 31 Plastic Fastener, cover fixing A111W6534F 4 32 Stay, lid supporting A117B0244F 1 33 Grommet, stay to bulkhead X036B6150Z 1 34 Retaining Clip, stay A082W6325F 1 35 Screw, No. 8 x 0.5", pan hd. Pozi., clip fixing A075W5034Z 1 36 Washer, flat, 3/16" x 0.5", black A075W4063Z 1 37 Stud Plate, bracket fixing, rear A117B0243F 1 38 Stud Plate, bracket fixing, front A117B0242F 1 39 Double Sided Tape, 5mm A117B0362V As req. 40 Double Sided Tape, 19mm A117B0361V As req. 41 Spacer Washer, M6 x 12.1 x 1.4, latch to bracket A075W4013Z 2 42 Shim, ABS, 1.6mm, hinge to clamshell/bulkhead A117B0386K 4 Function Code: 10.11, Page: 2 Function Code 10.11 Engine Cover Lid & Latch Mechanism Dep Part Description 43 Remarks Part Number Qty End Cap, PTFE, plunger, engine cover lift A117B6028H 1 44 Captive Nut, M6, bracket to bulkhead A117W3181F 3 45 'T' Handle Assembly, engine cover interior emergency release B121B0029F 1 Includes wire & barrel Option USA/Canada, A121B0029F R/B Function Code: 10.11, Page: 3 (v) $ \ / / / / / c{, z'$ ),>' ts}_r r---\, .F.trtrLLLt I .LI_\_\-\-LL-LLt-t-u,-LLr- , \ !t \-IF-LL , -Ft-\-F\\ FLLLLUi-l .!\-ILLLLI.I TILLLLLL :!FFF+!\' t|J tll J* F I1l Service Parts List Function Code 17.17 Interior Lamps Dep Part Description 01 Interior Lamp 02 Bulb, interior lamp, 5W Remarks Option Part Number Qty A082M6644F 1 1 Function Code: 17.17, Page: 1 2 3 4 12 10 17 1 6 5 13 21 6 16 5 20 14 6 5 17 8 18 9 19 7 15 17.21 Function Code 17.21 Windscreen Wiper Motor, Wipers & Washers Dep Part Description 01 Remarks Option Part Number Qty Wiper Drive Assembly, RHD A117M0104F 1 01a Wiper Drive Assembly, LHD A117M0143F 1 02 Wiper Arm A120M0005H 1 03 Wiper Blade B120M0006H 1 03a Wiper Arm/Blade Assembly B121B0057F 1 04 Flange Nut, M8 x 1.25, arm to spindle A111W3154F 1 05 Screw, M8 x 20, cap hd., motor bracket to body A111W7141F 3 06 Washer, M8, spring, motor bracket to body A075W4036Z 3 07 Cover, wiper motor, RHD Also fusebox mounting Elise B120B0134F 1 07a Cover, wiper motor, LHD Also fusebox mounting Elise B120B0133F 1 07b Cover, wiper motor, RHD Also fusebox mounting Exige B122U0010K 1 07c Cover, wiper motor, LHD Also fusebox mounting Exige B122U0011K 1 08 Screw, No.10 x ½", pozi., cover fix. A075W5040Z 2 09 Spire Nut No. 8, cover, wiper motor fix. A075W6016Z 2 10 Windscreen Washer Jet A082M6369F 2 11 Spacer, washer jet A111M6046K 2 12 Sleeve, washer jet Bonded over jet & spacer A111M0065F 1 13 Tube, 'T' piece to jet Cut to fit A116M0040V As req. 14 Tube, non return vave to 'T' piece Cut to fit A116M0040V As req. 15 Tube, bottle to non return valve Cut to fit A116M0040V As req. 16 'T' piece, washer tubing A111M6045K 1 Use until blade available Function Code: 17.21, Page: 1 Function Code 17.21 Windscreen Wiper Motor, Wipers & Washers Dep Part Description 17 Remarks Option Part Number Qty Valve, non return A100M6062H 1 18 Clip, hose to wiper motor bracket A079W6185F 1 19 Washer Bottle and Pump Assembly A116M0039F 1 20 Bracket, washer bottle mounting A117P0140F 1 21 Pop Rivet, bracket to boot bulkhead A089W6297F 3 Function Code: 17.21, Page: 2 1 WOODSTOCK DAB 53 2 5 3 4 17.27 Function Code 17.27 In Car Entertainment Dep Part Description 01 Radio/CD Player, Blaupunkt, DAB 54 Woodstock 01a Remarks Option Part Number Qty A120M6004F R/B A120M6014F 1 Radio/CD Player, Blaupunkt, CD33 Lausanne A120M6003F 1 01b Radio/CD Player, Blaupunkt, BPV755 A120M6008F 1 01c Radio/CD Player, Blaupunkt, CD34 Freiburg A120M6011F 1 01d Radio/CD Player, Blaupunkt, MP72 Los Angeles USA/Canada A121M6001F 1 01e Radio/CD Player, Blaupunkt, CD34 Venice Beach USA/Can. A121M6002F R/B A121M6010F 1 01f Radio/CD Player, Bosch Apacpulco MP54 US USA/Canada A120M6013F 1 02 Antenna, di pole, analogue A120M0018F 1 02a Antenna, di pole, DAB A120M0021F 1 03 Speaker Kit, rear, Blaupunkt GTX542 A120M6006F 1 03a Speaker Kit, rear, Bosch Bgx 542 A120M6015F 1 04 Speaker Kit, front, Bosch Odx 102 A120M6012F R/B A120M6016F 1 04a Grilles, front speakers USA/Canada A121M6008F 1 05 Blanking Plug, engine cover unused aerial hole A117U6010F 1 06 Co-axial Cable, antenna, analogue Not illustrated A120M0019F 1 06a Co-axial Cable, antenna, DAB Not illustrated A120M0022F 1 07 Tape, 3M Superbound 396, antenna to clamshell Not illus. sold per roll (32M) A120M6007F As req. Not illustrated Function Code: 17.27, Page: 1 OEM BATTERY NOT AVAILABLE FOR REPLACEMENT FOR REFERENCE, BCI CODE FOR A REPLACEMENT BATTERY IS 26R-6YR 'r-, l , / \ Y 0^\ \ A 0\ / ^o \U\ \ 'o 0\ / v \ ,/\U r \' , \0 b .:i/ :::x/*4*/ t, n J_ UT Function Code 17.31 Battery, Clamps, & Cables Dep Part Description 01 Remarks Option Part Number Qty Battery A116M6014F 1 02 Harness, battery, +VE & -VE B120M0007F 1 03 Earth Braid, chassis to engine/tranmission assy. A120M0008F 1 04 Retaining Clamp, inboard A120M0014F 1 05 Retaining Clamp, outboard A120M0015F 1 06 Nutplate, retaining clamps A120M0016F 2 07 Screw, M8, skt. button hd.,clamp fix. A075W7022F 1 08 Washer, flat, M8 x 16.6 x 1.4, clamp fix. A075W4020Z 1 09 Pop Rivet, nutplate to boot floor A111W6614F 4 10 Battery Cover/Handbook Holder A120U0033J 1 11 Binding Post Assembly Skuttle & electrics mounting plate A340M6007F 2 12 Nyloc Nut, M8 Front & rear earth points A075W3010Z 2 13 Washer, flat, M8 x 16.6 x 1.4 A075W4020Z 2 14 Screw, M8, flg. hd., braid to transmission casing 15 Cable, starter and alternator Not illustrated 16 Battery Lead, -VE Not illustrated 17 Battery Lead, +VE 18 1 B120M0009F 1 Exige A122M0007F 1 Not illustrated Exige A122M0006F 1 Bracket, battery post Not illustrated Exige A122B0147F 1 19 Shim, battery post bracket Not illustrated Exige A122B0148F 1 20 Rubber Mat, battery Not illustrated A120M0024F 1 Function Code: 17.31, Page: 1 1/2 3 5 8 10 11 9 4 6 12 7 17.33 Function Code 17.33 Security Alarm System Dep Part Description Remarks 01 Cobra Alarm Kit, 8186 02 Controller, 8186 system 03 Option Part Number Qty Comprises: controller, A117M6063F R/B immobiliser, keys, plus items 5/ 6 B117M6063F 1 Progammed for siren & microwave sensor A117M6049S 1 Screw, No.8 x 3/8", pan hd. pozi. controller to chassis A075W5031F 2 04 Immobiliser A117M6050S 1 05 Microwave Sensor A117M6048S 1 06 Siren Assembly Incl. bracket, fixings & item 6a A117M6047S 1 06a Bracket/Shield, siren Not illustrated, incl. in item 6 A117M6091S 1 06b Bracket, siren mounting Not illus., also see 46.03 A120K0018F 1 07 Transmitter Key A111M6100S 2 08 Microswitch, alarm activation, front access covers A111M6037F 3 09 Bracket, front microswitch mounting A120B0127F 2 10 Pop rivet, domed, black, brackets to clamshell A082W6512F 6 11 Microswitch, alarm activation, engine cover Located in striker/lift assembly A111B6035F 1 12 Microswitch, alarm activation, doors Also for courtesy lamp A111M6035F 2 13 Cover Assembly, alarm module Not illustrated A117M0148J 1 Function Code: 17.33, Page: 1 ,i\ t\ lel \r I i \ t \ ! ./-^--.- t, tll 1 l:|E Function Code 18.01 Heater/ Air Conditioning Assemblies, Housings Dep Part Description 01 Remarks Option Part Number Qty Heater/AC Housing Assembly AC cars A117P0029F 1 01a Heater Housing Assembly heater cars A117P0124F 1 02 Actuator, heater/AC flaps A117M6052S 1 03 Expansion Valve A117P0122S 1 04 Cover, actuator A117P0158K 1 05 Thermostat Unit Includes thermistor A120P6004S 1 06 Drive Belt, heater flap Not illustrated A117P6001S 1 07 Screw, M6 x 20, hex. flg. hd., AC/htr. assy. to chassis Not illustrated A117W2203F 2 Also see 18.03 Function Code: 18.01, Page: 1 5 10 2 28 28 27 17 11 16 4 18 23 7 14 15 20 24 33 31 25 28 34 31 29 12 19 13 28 3 6 30 29 9 26 32 8 18.03 21 22 1 Service Parts List Function Code 18.03 AC Components, Pipes, Hoses Dep Part Description 01 Remarks Option Part Number Qty Condenser A117P0042H 1 02 Reciever Drier/Bracket Assembly, LHD A117P0060F 1 02a Reciever Drier/Bracket Assembly, RHD A117P0058F 1 03 Expansion Valve A117P0122S 1 04 Refrigerant Pipe, reciever drier to condenser, LHD A120P0007F 1 04a Refrigerant Pipe, reciever drier to condenser, RHD A120P0006F 1 05 Refrigerant Pipe, reciever drier to expansion valve, LHD A120P0005F 1 05a Refrigerant Pipe, reciever drier to expansion valve, RHD A117P0049F 1 06 Refrigerant Pipe, condenser to sill connection A117P0051F 1 07 Refrigerant Pipe, expansion valve to sill connection, LHD A120P0009F 1 07a Refrigerant Pipe, expansion valve to sill connection, RHD A120P0008F 1 08 Refigerant Pipe, high pressure, rear to front connections A117P0138F 1 09 Refigerant Pipe, suction line, rear to front connections A117P0139F 1 10 Pipe/Hose Assembly, compressor discharge B120P0003F 1 11 Pipe/Hose Assembly, compressor suction B120P0001F 1 12 Clamp Plate, pipes to expansion valve A082P4402F 1 13 Bracket, pipes to chassis RH rear A120P0010F 1 14 Screw, hex. hd., plate to chassis 3 Function Code: 18.03, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 18.03 AC Components, Pipes, Hoses Dep Part Description Remarks Option Part Number Qty 15 Washer, flat, plate to chassis 16 'O' Ring, compressor to suction line A120P6002H 1 17 'O' Ring, compressor to discharge line A120P6001H 1 18 Screw, flg. hd., pipes to compressor 19 Bracket, condenser to radiator, front A117P0098H 1 20 Bracket, condenser to radiator, rear A117P0099H 1 21 Nyloc Nut, M6, condenser to radiator front A075W3009F 2 22 Washer, flat, M6, condenser to radiator front A075W4013Z 2 23 Screw, M6 x 16, hex. hd., bracket to chassis A075W1028Z 2 24 Washer, spring, M6, bracket to chassis A075W4035Z 2 25 Washer, flat, M6 x 12.1 x 1.4, bracket to chassis A075W4013Z 2 26 Pressure Relief Valve A111P6030H 1 27 Trianary Switch A117P0059F 1 28 'O; Ring, No. 6, pipe joints A082P6078F 4 29 'O; Ring, No, 8, pipe joints A082P6079F 2 30 'O' Ring, No 10, expansion valve to evaporator A082P6080F 2 31 'O; Ring, No.12, pipe joints A082P6081F 2 32 Clamp Plate, valve to evaporator A082P4401F 1 33 Screw, M5 x 40, cap hd. skt., valve to clamp A100W7081F 2 34 Screw, M6 x 16, cap hd. skt., clamp to valve A075W7017F 1 3 2 Function Code: 18.03, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 c e V / ,P- co I t, tll !- @ o I lo J tj' Function Code 18.05 Heater, Pipes, Hoses Dep Part Description 01 Remarks Part Number Qty Pipe, heater feed B116K0022F 1 02 Pipe, heater return B116K0020F 1 03 Hose, re-circ pump to feed pipe B120K0003F 1 04 Hose Assembly, return pipe to engine D120K0004F 1 05 Hose, heater inlet, RHD A117P0024F 1 05a Hose, heater inlet, LHD A117P0123F 1 06 Hose, heater outlet, RHD A117P0022F 1 06a Hose, heater outlet, LHD A117P0021F 1 07 Saddle Clip, cable tie, pipes to chassis A082W6324F 14 08 Cable Tie, pipes retention A075W6038F 14 09 Blind Rivet, saddle clamp to chassis A085W6259F 6 10 Blind Rivet, saddle clamp to chassis A111W6613F 6 11 Blind Rivet, saddle clamps to chassis A111W6614F 4 12 Foam Strip, self adhesive, pipe protection A082U6067F As req. 13 Hose Clamp, 41mm, hoses to pipes/spigots A116K6016F 4 14 Grommet, pipes through baffle A111P0003K 2 15 Hose Clip, hoses to pipes/heater spigots A079K6019Z 4 16 Clip, cable tie, front pipes securing A120W6779F 2 Also see 46.01, includes bleed Option Function Code: 18.05, Page: 1 1 18.07a Function Code 18.07a AC/Heater Interior Blower Motor Dep Part Description 01 Remarks Part Number Qty Blower & Motor Assembly, RHD A117P0025F 1 01a Blower & Motor Assembly, LHD A117P0026F 1 02 Resistor, blower motor A117P6000S 1 Not illustrated Option Function Code: 18.07a, Page: 1 1 2 6 4 3 18.09a 5 Function Code 18.09a AC/Heater Driver Operated Controls Dep Part Description Remarks Option Part Number Qty 01 Switch Panel Assembly, AC, RHD Incl. temp, fan & dist. Switches AC cars A117P0147F 1 01a Switch Panel Assembly, AC, LHD Incl. temp, fan & dist. Switches AC cars A117P0146F 1 01b Switch Panel Assembly, heater, RHD Incl. temp, fan & dist. Switches Heater cars A117P0149F 1 01c Switch Panel Assembly, heater, LHD Incl. temp, fan & dist. Switches Heater cars A117P0148F 1 02 Screw, Ejot 1452K 50 x 18, black, panel fix. A082W5187F R/B A117W5277F 4 03 Knob, brushed/polished, climate controls B117U0036F 3 03a Knob, polished, climate controls A117U0201F 3 04 Switch, AC, blue tell-tale A117M0026F 1 05 Switch, Recirculation, blue tell-tale A117M0026F 1 06 Switch, 3 speed fan A117M6053S 1 Function Code: 18.09a, Page: 1 1 3 2 18.12 Function Code 18.12 AC/Heater Air Distribution Plenum Dep Part Description 01 Remarks Option Part Number Qty Air Distribution Plenum, LHD A117P0041F 1 01a Air Distribution Plenum, RHD A117P0042F 1 02 Actuator, distribution flaps A117M6052S 1 03 Hose, heater to plenum A117P0156F 1 Function Code: 18.12, Page: 1 6 16 7 4 7 3 8 See 10.02a 5 2 4 7 7 8 17 12 2 9 15 6 7 13 3 8 14 1 4 17 2 18.13 11 10 Function Code 18.13 Air Trunking, Ducts & Ventilators Dep Part Description 01 Remarks Option Part Number Qty Fascia Top Ventilator/Demister A117U0035F 4 02 Face Level Vent A117U6003F 4 03 Retaining Ring, FLV A117P0086F 2 04 Adaptor, vent to trunking A117P0063F 4 05 Trunking, centre face level vents A117P0068F 2 06 Trunking, outer face level vents A117P0069F 2 07 Foam Seal, self adhesive, 19 x 3mm, adaptors to trunking A082U6067F 1.28m 08 Foam Seal, self adhesive, 10 x 6mm, FLV to adaptor A100B0431V 0.8m 09 Blanking Panel, FVL plenum, LHD/RHD A117P0084K 1 10 Deflector, footwell, RHD A120U0026F 1 10a Deflector, footwell, LHD A120U0027F 1 11 Duct, intermediate, FLV centre USA/Canada A121U0029F 1 12 Duct, side FLV, RH USA/Canada A121U0028F 1 13 Duct, side FLV, LH USA/Canada A121U0027F 1 14 Gasket, FLV USA/Canada A121V0006H 4 15 Duct, FLV centre USA/Canada B121P0002H 1 16 Duct, air distribution, demist USA/Canada A121P0001H 1 17 Screw, self tap., No.10 x 3/4", ducts to panels USA/Canada A075W5040Z 28 Bond to plenum to make LHD or RHD assembly Includes foam gaskets P/O fascia top panel assy. Function Code: 18.13, Page: 1 8 6 5 2 9 7 4 3 1 18.14 Function Code 18.14 AC Air Recirculation System Dep Part Description 01 Remarks Option Part Number Qty Intake Duct/Fresh Air Flap Assembly, LHD AC cars A117P0089F 1 01a Intake Duct/Fresh Air Flap Assembly, RHD AC cars A117P0088F 1 01b Intake Duct, heater, LHD Heater cars A117P0134F 1 01c Intake Duct, heater, RHD Heater cars A117P0135F 1 02 Recirc. Air Plenum, LH, RHD Without aperture AC cars A120P0011F 1 02a Recirc. Air Plenum, LH, LHD With aperture AC cars B117P0037F 1 03 Recirc. Air Plenum, RH, RHD With aperture AC cars B117P0036F 1 03a Recirc. Air Plenum, RH, LHD Without aperture AC cars A120P0012F 1 04 Actuator, fresh air flap AC cars A117M6052S 1 05 Blanking Panel, alloy Driver footwell AC cars A117P0123F 1 06 Deflector Panel, alloy Passenger footwell AC cars A117P0126F 1 07 Pop Rivet, panels to chassis AC cars A111W6603F 6 08 Cover, actuator, RHD AC cars A117P0159K 1 09 Cover, actuator, LHD AC cars A117P0160K 1 Function Code: 18.14, Page: 1 6 7 8 5 4 9 10 3 2 12 9 11 19.01 Function Code 19.01 Labels,Certificates, Literature etc. Dep Part Description Remarks Option Part Number 01 Certificate of Conformity Contact Lotus Type Approval All models/markets Not listed 1 02 Label, 'E' mark Europe A120U0018F 1 03 Label, brake fluid warning A082U7623F 1 04 Label, headlamp levelling, 1.5% Europe B082U7039F 2 05 Label, VIN number, windscreen USA/Canada A121U0121F 1 06 Label, tyre loading Elise, Australia D117U0273F 1 06a Label, tyre loading Exige, Australia B120B0117F 1 07 Label, VIN C111U0005K 1 08 Label, premium unleaded fuel A082U7800F 1 09 Label, jacking point A111U0239F 2 10 Label, luggage loading B111U0007F 1 11 Label, shear panel warning A111A0213F 2 12 Label, fuel consumption A120U0042F 1 13 Label, hard top instuction directive Not illus. on hard top inner A116V0185F 1 14 Label, tyre placard Not illustrated USA/Canada A121U0008F 1 15 Label, engine data Not illustrated Australia A120U0038F 1 16 Label, tyre and loading information Not illus., on LH 'B' post USA/Canada B121U0007F 1 16a Label, tyre and loading information, Yokohama A048 Not illustrated USA/Canada A121U0136F 1 17 Label, certification Not illus., on RH 'B' post USA/Canada A121U0006F 1 18 Label, water ingress Not illus., on RH cantrail UK version B120U0032F 1 18a Label, water ingress Not illus., on LH cantrail USA version A121U0054F 1 Beneath headlamp covers Special order only A111U0007F R/B Australia Qty Function Code: 19.01, Page: 1 Function Code 19.01 Labels,Certificates, Literature etc. Dep Part Description Remarks Option Part Number Qty 19 Label, emmision control Not illus., on LH engine cover USA/Canada B121U0009F 1 20 Label, vacuum routing Not illus., on RH engine cover USA/Canada A121U0010F 1 21 Label, smog index Not illustrated USA/Canada A121U0011F 1 22 Label, emmision control info. Not illustrated USA/Canada A121U0012F 1 23 Label, federal exemption (headlamps) Not illustrated USA/Canada A121U0143F 1 24 Label, federal exemption (bumpers) Not illustrated USA/Canada A121U0152F 1 25 Label, fuel filler cap Not illustrated USA/Canada A121U0013F 1 26 Label, airbag warning visible Not illus., on sunvisor USA/Canada A082U6305F 2 27 Label, child seat inner Not illus., on sunvisor USA/Canada B082U6306F 2 28 Label, removable child seat Not illus., on gearlever USA/Canada A082U6317F 1 29 Label, SIR warning Not illus., on battery cover USA/Canada A082U7350F 1 30 Label, ECM, non AC Not illustrated Exige A122E0005F 1 30a Label, ECM, AC Not illustrated Exige A122E0006F 1 31 Label, fuel consumption Not illustrated Australia A122B0116F 1 Function Code: 19.01, Page: 2 1 19.03 Function Code 19.03 Owner's Handbooks & Service Notes Manuals Dep Part Description Remarks Option Part Number Qty 01 Owners Handbook Includes maintenance record 111R/Exige A120T0324J 1 01a Owners Handbook Includes maintenance record Elise, USA/Canada A121T0324J 1 02 Service Notes A120T0327J 1 03 Service Parts List A120T0325J 1 04 Workshop Manual, engine 1 B120T0327J 1 05 Workshop Manual, engine 2 C120T0327J 1 06 Workshop Manual, transmission D120T0327J 1 07 Labour Times Schedule A120T0328J 1 08 Maintenance Schedule Pack (25) LSL460 LSL 462 1 09 PDI Form Pack (25) PLEASE REFER ON TO LOTUS NOTES KNOWLEDGE BASE BASE LSL345C USE FORM FOUND LOTUS NOTES KNOWLEDGE 1 Function Code: 19.03, Page: 1 8 9 10 14 2 15 16 1 18 17 13 7 6 5 4 12 11 3 30.01 14 16 15 Function Code 30.01 Chassis, Subframe Dep Part Description Remarks Option Part Number Qty 01 Partial Body Assembly, heater, RHD Includes subframe Elise heater A120A0112S 1 01a Partial Body Assembly, heater, LHD Includes subframe Elise heater A120A0113S 1 01b Partial Body Assembly, AC, RHD Includes subframe/AC pipes Elise AC A120A0114S 1 01c Partial Body Assembly, AC, LHD Includes subframe/AC pipes Elise AC A120A0115S 1 01e Partial Body Assembly, heater, oil coolers, RHD Includes subframe, oil pipes Elise heater/oil cooler A120A0116S 1 01f Partial Body Assembly, heater, oil coolers, LHD Includes subframe, oil pipes Elise heater/oil cooler A120A0117S 1 01g Partial Body Assembly, AC, oil coolers, RHD Includes subframe/AC/oil pipes Elise AC/oil cooler A120A0118S 1 01h Partial Body Assembly, AC, oil coolers, LHD Includes subframe/AC/oil pipes Elise AC/oil cooler A120A0119S 1 01i Partial Body Assembly, Exige heater, RHD Includes subframe, oil pipes Exige heater A122A0036S 1 01j Partial Body Assembly, Exige heater, LHD Includes subframe, oil pipes Exige heater A122A0037S 1 01k Partial Body Assembly, Exige AC, RHD Includes subframe/AC/oil pipes Exige AC A122A0038S 1 01l Partial Body Assembly, Exige AC, LHD Includes subframe/AC/oil pipes Exige AC A122A0039S 1 01m Partial Body Assembly, AC, dual airbag, LHD, federal Includes subframe/AC/oil pipes Elise, USA/Canada A121A0017S 1 02 Rear Sub Frame, galvanised B120A0001F R/B C120A0001F 1 03 Shear Panel, fuel tank bay closing panel B120A0065F 1 04 Screw, M8 x 25, hex. hd., shear panel fix A111W1156F 10 05 Washer, flat, M8 x 21 x 1.6 A111W4159F 10 06 Washer, flat, M8 x 16.6 x 1.4 A111W4164F 5 07 Nyloc Nut, M8 A907E6284F 5 08 Blanking Panel, RH, toe board air vents Heater cars A111P0490K 1 09 Blanking Panel, LH, toe board air vents Heater cars A111P0489K 1 Function Code: 30.01, Page: 1 Function Code 30.01 Chassis, Subframe Dep Part Description 10 Pop Rivet, blanking panel fix 11 Setscrew, M5 x 16, hex. hd., shear panel to chassis/sill 12 Remarks Option Part Number Qty A085W6259F 8 Also see 10.25 A111W1163F 6 Washer, flat, M5 x 25 x 1.4, shear panel to chassis/sill Also see 10.25 A082W4098F 6 13 Spirenut, M5, shear panel to chassis/sill Also see 10.25 B100W6372F 6 14 Shim, subframe to chassis A116A0076F 2 15 Bolt, M12 x 60, hex. hd.,subframe to chassis A075W2070Z 4 16 Washer, flat, M12 x 23.5 x 2.3, subframe to chassis A075W4028Z 4 17 Washer, flat, M12 x 24 x 1.6, subframe to chassis lower A075W4071F 2 18 Nyloc Nut, M12, subframe to chassis lower A075W3012Z 2 19 Grommet, blanking, unused steering column hole Not illustrated A117W6783F 1 20 Grommet, blanking, tank bar rear Not illustrated A121W6755F 1 A111A6003F R/B Function Code: 30.01, Page: 2 1 2 8 7 3 4 5 10 9 7 6 30.02 Service Parts List Function Code 30.02 Seat Belt Mounting Frame, Stays Dep Part Description 01 Remarks Option Part Number Qty Seat Belt Mounting Frame 111R/Exige B117A0145F 1 01a Seat Belt Mounting Frame USA/Canada A121A0015F R/B B117A0145F 1 01b Seat Belt Mounting Frame, T45 Optional + 240R A122A0046F 1 02 Backstay, frame, LH B120A0069F 1 02a Backstay, frame, LH, T45 A122A0049F 1 03 Backstay, frame, RH B120A0070F 1 03a Backstay, frame, RH For federal fuel filler support, see 44.01d C120A0070F 1 03b Backstay, frame, RH, T45 Silver finish A122A0050F 1 04 Screw, M8 x 25, cap hd., frame to chassis A111W7132F 8 05 Washer, flat, M8 x 16.6 x 1.4, frame to chassis A075W4020Z 8 06 Shim, base plate B111A0071F 2 07 Screw, M10 x 35, flg. hd., stay fixing A116W5247F 4 08 Mounting Bar, 4 point harness Exige option A122A0032F 1 09 Screw, M10 x 30, hex. flg. hd., bar to frame Exige option A116W5272F 2 10 Washer, flat, M10 x 38, bar to frame Exige option A122A0033F 2 11 Permabond A130 A912E7034F As req. Centre boss for towing eye Silver finish Optional + 240R Optional + 240R Not illustrated, for use with screws, item: 4 Function Code: 30.02, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 15 17 16 17 22 25 16 26 16 16 24 25 16 28 11 29 10 13 19 27 9 5 20 6 43 12 21 23 8 4 7 37 38 39 13 1 14 41 16 40 30 16 See 34.01 30 16 23 3 35 42 34 33 2 36 31 32 34 33 22 See 33.01 31.01 16 18 14 35 Service Parts List Function Code 31.01 Front Suspension, Incl. Hubs Dep Part Description 01 Remarks Option Part Number Qty Hub Carrier, LH A116C0001F 1 01a Hub Carrier, RH A116C0002F 1 02 Hub/Bearing Assembly, with wheel speed sensor A117D6005F 2 03 Screw, M12 x 40, cap hd., hub assy. to hub carrier A116W1170F 6 04 Steering Arm, LH A116C0003F 1 04a Steering Arm, RH A116C0004F 1 05 Bolt, M10 x 40, 10.9G, cap hd., steering arm to hub carrier A117W7211F 2 06 Bolt, M10 x 60, 10.9G, cap hd., steering arm to hub carrier A117W7213F 2 07 Shim, 1mm, camber adjustment A111C0062F As req. 07a Shim, 3mm, camber adjustment A111C0064F AS req. 08 Shim/Bracket, connector retaining, LH B116C0013F 1 08a Shim/Bracket, connector retaining, RH B116C0012F 1 09 Bush, upper wishbone rear pivot A116C0035F 2 10 Damper/ABS Unit Mounting Bracket, LH, LHD B116C0011F 1 10a Damper/ABS Unit Mounting Bracket, RH, B116C0010F 1 11 Damper Elise A120C0007H 2 11a Damper Exige A122C0007H 2 A116C0011F R/B Function Code: 31.01, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 31.01 Front Suspension, Incl. Hubs Dep Part Description 11b Remarks Option Part Number Qty Damper, federal USA/Canada A121C0003H 2 11c Damper, one way adjustable Optional A120C0018H 2 12 Road Spring Elise A116C0015H 2 12a Road Spring Exige, Elise option A122C0008H 2 13 Bolt, M10 x 55, hex. hd., damper bottom fix. A079W2057F 2 14 Bush, lower wishbone/upper wishbone front pivots A116C0068F 6 15 Bolt, M10 x 70, hex. hd., damper top fix. A075W2058Z 2 16 Washer, flat, M10 x 21 x 2 B111W4163F 22 17 Spacer, damper to top mounting bracket A111C0061F 4 18 Nyloc Nut, M10, damper fixings A100W3112F 4 19 Bolt, M8 x 25, hex, hd., bracket to chassis A111W1156F 4 20 Washer, flat, M8 x 16.6, bracket to chassis A111W4164F 4 21 Nyloc Nut, M8, bracket to chassis A075W3010Z 4 22 Ball Joint C111C6012F 4 23 Nyloc Nut, M12 x 1.5, ball joint A100C6019F 2 24 Pivot Bolt, M10 x 80, hex. hd., wishbone upper front A075W2061Z 2 25 Nyloc Nut, M10, wishbone upper to chassis A100W3112F 4 26 Shim, castor adjustment A111C0077F 6 27 Snubber Washer, rubber coated, upper wishbone A111C0081F 2 28 Shim, castor adjustment, small A111C0080F 8 29 Pivot Bolt, M10 x 75mm, hex. hd., wishbone upper rear A075W2059Z 2 Replace in car sets Black finish Function Code: 31.01, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 31.01 Front Suspension, Incl. Hubs Dep Part Description Remarks 30 Nyloc Nut, M10, wishbone lower to chassis fix 31 Wishbone Assembly, lower, LH 31a Wishbone Assembly, lower, RH 32 Option Part Number Qty A100W3112F 4 Includes balljoint & bushes A117C0035J 1 Includes balljoint & bushes A117C0034J 1 Anti-Roll Bar Drop Link A111C0063F 2 33 Washer, flat, M10 x 24 x 1.5, drop link fix A075W4023F 4 34 Nyloc Nut, M10 x 1.25, drop link fix A111W3152F 4 35 Toe Link Rod B116D0053S 2 36 Anti-Roll Bar A111C0111F 1 37 Clamp Bracket, A/R bar A111C0107F 2 38 Pivot Bush, rubber, A/R bar. A111C0094F 2 39 Spacer Plate, A/R bar fixing A111C0109F 2 40 Screw, M8 x 30, skt. cap hd., A/R bar clamp bracket fixing A117W7215F 4 41 Washer, flat, M8 x 16.5 x 1.6, bracket to chassis upper A111W4175F 2 42 Washer, flat, M8 x 25 x 1.4, bracket to chassis lower A111W4156F 2 43 Wishbone Assembly, upper, LH A117C0029J 1 43a Wishbone Assembly, upper, RH A117C0030J 1 44 Anti-Roll Bar, sport, adjustable Not illustrated Optional A111C0134S 1 45 Mounting Clamp, nylon, A/R bar Not illustrated Optional B111C0052F 2 46 Bush, A/R bar mount to chassis Not illustrated Optional A111C0060F 2 47 Bolt, M5 x 45, cap hd., clamp fixing Not illustrated Optional A082W2106F 2 A111W1161F R/B Function Code: 31.01, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 31.01 Front Suspension, Incl. Hubs Dep Part Description Remarks Option Part Number Qty 48 Washer, flat, M5 x 10 x 1.0, clamp fixing Not illustrated Optional A075W4011Z 2 49 Nyloc Nut, M5, clamp fixing Not illustrated Optional A100W3113F 2 50 Pivot Bolt, M10 x 45, hex. hd., front lower wishbone Not illus, also A/R bar clamp Optional A075W2065F 2 Function Code: 31.01, Page: 4 2005/02 UPDATE ISSUED SEPTEMBER 2005 8 9 10 22 19 19 26 12 21 7 10 18 16 17 14 20 15 10 19 7 23 16 6 5 8 17 16 18 16 9 26 19 4 37 24 13 13 32 1 25 3 29 2 31 26 33 See 33.01 See 34.01 35 46 39 36 38 9 9 34 45 10 27 28 12 30 42 40 41 43 31.03 44 Service Parts List Function Code 31.03 Rear Suspension, Incl. Hubs Dep Part Description 01 Remarks Option Part Number Qty Hub Carrier, LH A116D0097F 1 01a Hub Carrier, RH A116D0096F 1 02 Hub/Bearing Assembly, with wheel speed sensor A117D6005F 2 03 Screw, M12 x 40, cap hd., hub assy. to hub carrier A116W1170F 6 04 Ball Joint Carrier B111D0055F 2 05 Bolt, M10 x 50, 10.9G, cap hd., carrier to hub carrier A117W7212F 4 06 Shim, camber adjustment D111D0052F As req. 07 Pivot Bolt, M10 x 60, hex. hd., upper wishbone F & R A079W2055F 4 08 Bolt, M10 x 55, hex. hd., damper fixing A079W2057F 4 09 Washer, flat, M10 x 21 x 2, damper fixing B111W4163F 8 10 Nyloc Nut, M10, 8.8 grade, damper/upper wishbone fixing A100W3112F 8 11 Wishbone Assembly, lower, LH Includes balljoint & bushes C116D0081J 1 11a Wishbone Assembly, lower, RH Includes balljoint & bushes C116D0080J 1 12 Ball Joint C111C6012F 4 13 Nyloc Nut, M12 x 1.5, balljoint A100C6019F 4 14 Bracket, lower wishbone to chassis, LH B120D0023F R/B C120D0023F 1 14a Bracket, lower wishbone to chassis, RH C120D0024F R/B D120D0024F 1 15 Bolt, M10 x 40, bracket to chassis A116W2206F 8 Black finish Function Code: 31.03, Page: 1 2005/02 UPDATE ISSUE SEPTEMBER 2005 Function Code 31.03 Rear Suspension, Incl. Hubs Dep Part Description Remarks 16 Washer, flat, M10 x 21 x 2, bracket to chassis Black finish 17 Option Part Number Qty B111W4163F 8 Spacer, M10, bracket to chassis A111D0147F 8 18 Nyloc Nut, M10, bracket to chassis A100W3112F 8 19 Tab Washer, upper pivot bolts A116D0031F 8 20 Tab Washer, lower front pivot bolt A116D0032F 2 21 Road Spring Elise A120D0012H 2 21a Road Spring Exige A122D0006H 2 22 Damper Elise A120D0011H 2 22a Damper Exige, Elise option A122D0008H 2 22b Damper, federal USA/Canada B121D0003H 2 22c Damper, one way adjustable Optional A120D0046H 2 23 Pivot Bolt, M10 x 65, hex. hd., lower wishbone front A075W2056F 2 24 Wishbone Assembly, upper, LH Includes balljoint & bushes B116D0085J 1 24a Wishbone Assembly, upper, RH Includes balljoint & bushes B116D0084J 1 25 Bush, lower wishbone front pivot (short) A116C0067F 4 26 Bush, lower wishbone rear/upper wishbones A116C0068F 6 27 Nut, castellated, shaft to hub A116D6001F 2 28 Washer, flat, nut to shaft A082D6025F 2 29 Locknut, flange, cleave, M10 x 1.25, inner toe link fixing A117W3189F 2 30 Ball Joint, tapered, outer, RH thread, M10 x 1.25 x 45 stud A117D0089S 2 31 Nyloc Nut, M12, balljoint to hub carrier A100C6019F 2 A116W3183F R/B Function Code: 31.03, Page: 2 2005/02 UPDATE ISSUE SEPTEMBER 2005 Function Code 31.03 Rear Suspension, Incl. Hubs Dep Part Description 32 Remarks Option Part Number Qty Ball Joint, inner, LH thread, M10 x 1.25 x 60 stud A117D0090S 2 33 Locknut, M12, RH thread, ball joint to rod A111W3150F 2 34 Locknut, M12, LH thread, ball joint to rod A111W3149F 2 35 Toe Link Rod B116D0053S 2 36 Toe Link Assembly A117D0088F 2 37 Shim/Bracket, connector retaining, LH B116C0013F 1 37a Shim/Bracket, connector retaining, RH B116C0012F 1 38 Split Pin, nut to shaft A116D6003F 2 39 Crossbrace, track control arms See Service Bulletin 2005/04 Optional + 240R A120D0040F 1 40 Spacer, joint to subframe See Service Bulletin 2005/04 Optional + 240R A120D0035F 2 41 Adaptor Lug See Service Bulletin 2005/04 Optional + 240R A120D0037F 2 42 Turnbuckle Adjuster Screw See Service Bulletin 2005/04 Optional + 240R A120D0039F 2 43 Pivot Bolt, M10 x 120 x 1.25, hex. hd., lower pivot/TCA See Service Bulletin 2005/04 Optional + 240R A120W2212F 2 44 Spherical Balljoint, inner See Service Bulletin 2005/04 Optional + 240R A120D0036F 2 45 Locknut, M12, LH thread, adjuster screw See Service Bulletin 2005/04 Optional + 240R A111W3149F 2 46 Locknut, M12, RH thread, adjuster screw See Service Bulletin 2005/04 Optional + 240R A111W3150F 2 A116D0090F R/B Function Code: 31.03, Page: 3 2005/02 UPDATE ISSUE SEPTEMBER 2005 3 4 5 2 12 1 14 13 2 6 11 10 7 3 8 9 4 5 32.01 Service Parts List Function Code 32.01 Rack & Pinion, & Lower Column Dep Part Description Remarks Option Part Number Qty 01 Steering Rack Assembly, RHD Use seal A120H0002F A117H0020F R/B A117H0052F 1 01a Steering Rack Assembly, LHD Use seal A120H0002F A117H0021F R/B A117H0053F 1 02 Gaiter, steering rack B111H6016F 2 03 Lock Nut, M12 , track rod end to track rod A111W3124F 2 04 Track Rod End/Ball Joint A117H0009F 2 05 Nyloc Nut, M10, track rod end to steering arm A111W3157F 2 06 Intermediate Steering Shaft Assembly D111H0003F 1 07 Adjuster Plate, rack height setting (6 notch) A111H0017F 2 08 Washer, flat, M8, rack mounting A075W4020Z 2 09 Setscrew, M8 x 25, hex. hd., rack mounting A082W1110F 2 10 Setscrew, M10 x 30, hex. hd., rack mounting A100A6028F 2 11 Washer, flat, M10, rack mounting A075W4024Z 2 12 Bolt, M8 x 40, hex. hd., 10.9 grade, steering shaft to U/J A918W2171F 4 13 Nyloc Nut, M8, steering shaft to U/J A075W3010Z 4 14 Grommet, steering shaft thro' bulkhead Racks prior to A117H0052/53 A082H6046F 1 14a Seal, steering shaft thro' bulkhead Racks A117H0052/53 A120H0002F 1 Includes nut, item: 5 Includes both universal joints C111H0003F R/B Function Code: 32.01, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 13 15 16 20 19 14 7 14 18 9 23 20 See 17.05 16 10 15 20 12 8 1 17 4 11 16 16 15 16 22 3 17 6 21 2 5 2a See 17.05 32.05 Function Code 32.05 Upper Column, Wheel, Steering Lock Dep Part Description Remarks Option Part Number Qty 01 Steering Wheel Assembly Silver crash pad Standard A117H0030J 1 01a Steering Wheel Assembly Red alcantara crash pad A117H0031J 1 01b Steering Wheel Assembly Black tooled leather crash pad A117H0047J 1 01c Steering Wheel Assembly Cranberry red tooled leather c/p A117H0049J 1 01d Steering Wheel Assembly Harvest brown tooled leather c/p A117H0050J 1 01e Steering Wheel Assembly Ingleton biscuit tooled leather c/p A117H0051J 1 01f Steering Wheel Assembly Grey synthetic leather crash pad A120H0001J 1 02 Horn Push, (less badge) A111H6021H 1 02a Horn Badge A111H6023H 1 03 Crash Pad, silver A117H0016S 1 03e Crash Pad, black tooled leather A117H0042S 1 03f Crash Pad, melrose blue tooled leather A117H0043S 1 03g Crash Pad, cranberry red tooled leather A117H0044S 1 03h Crash Pad, harvest brown tooled leather A117H0045S 1 03i Crash Pad, ingleton biscuit tooled leather A117H0046S 1 04 Lock Plate, steering wheel A111H6009F 1 05 Horn Contact Plate A111H6008F 1 06 Upper Steering Column A117H6001F 1 07 Bracket, switch module mounting B111H0006F 1 07a Bracket, switch module mounting, federal A121H0001F 1 08 Column Mounting Bracket, RH E117U0016F 1 Standard Includes ign. switch/steering lock Dual SIR cars USA/Canada Function Code: 32.05, Page: 1 Function Code 32.05 Upper Column, Wheel, Steering Lock Dep Part Description 09 Remarks Option Part Number Qty Bracket, forward column mounting B111H0004F 1 10 Column Mounting Bracket, LH E117U0135F 1 11 Nutplate, upper column support B111H0007F 2 12 Pop Rivet, nutplate to bracket A111W6586F 2 13 Bolt, M8 x 35, hex. hd., column to bracket A075W2038D 2 14 Washer, flat, M8 x 20 x 2.5 A079W4019F 3 15 Setscrew, M6 x 16, side to forward brk/chassis A075W1028Z 4 16 Washer, flat, M6 x 12.1 x 1.4 A075W4013Z 8 17 Nyloc Nut, M6 A907E6258F 4 18 Setscrew, M8 x 16 hex. hd., front mounting A075W1036Z 1 19 Washer, spring, M8 A075W4036Z 1 20 Rubber Beading, bracket edge protection B075U6054V 0.3M 21 Steering Lock Housing A111H6003S 1 22 Washer, spring, M6 A075W4035F 2 23 Steering Wheel Assembly, SIR Includes rotary connector A116U0085F 1 24 Shear Bolt, steering lock Not illustrated A111H6026S 2 Excluding lock barrel, see 10.17, item 1 USA/Canada Function Code: 32.05, Page: 2 12 1 14 2 13 1 11 8 10 3 7 9 6 4 9 5 33.01 Function Code 33.01 Brake Discs & Calipers Dep Part Description 01 Brake Disc, cross drilled 02 Brake Caliper, rear, RH 02a Brake Caliper, rear, LH 03 Brake Pad Set, rear 04 Brake Caliper, front RH 04a Remarks Part Number Qty C117J0031F 4 Includes brake pads, T4139 A116J0080F 1 Includes brake pads, T4139 A116J0079F 1 B117J0085S 1 Includes brake pads, T4139 A117J0132F 1 Brake Caliper, front LH Includes brake pads, T4139 A117J0131F 1 04b Brake Caliper, front, black, RH Includes brake pads, T4139 B117J0134F 1 04c Brake Caliper, front, black, LH Includes brake pads, T4139 B117J0133F 1 05 Brake Pad Set, front B117J0084S 1 05a Shims, self adhesive, pad front, RH Not illustrated A117J0014H 1 05b Shims, self adhesive, pad front, LH Not illustrated A117J0015H 1 06 Anti-Rattle Spring, front brake pads B111J0098H 2 07 Pin, front pad retaining B111J0123H 4 08 ' R' clip, pin retention A075W6175F 4 09 Screw, M6 x 16, csk., skt., hd., disc to hub A918W7120F 4 10 Nipple Cover, front brake bleed A111J6029F 2 11 Bolt, M10 x 65, cap hd., front caliper fixing A111W7144F 4 12 Bolt, M10 x 80, hex. hd., rear caliper fixing B082W1113F 2 13 Bolt, M8 x 60, cap hd., rear caliper fixing A111W1166F 2 14 Washer, flat, M10 x 20.5, rear caliper upper fixing bolt A075W4024Z 2 15 Sliding Pin Bush Kit, rear calipers A082J6162S 2 Black finish Includes sleeves, boots & seals Option Function Code: 33.01, Page: 1 Function Code 33.01 Brake Discs & Calipers Dep Part Description Remarks 16 Piston Retraction Tool, rear calipers Not illustrated Option Part Number Qty T000T1242F 1 Function Code: 33.01, Page: 2 10 11 12 13 12 1 9 12 13 20 2 3 7 8 12 13 44 45 5 24 21 4 18 40 27 16 17 6 14 15 41 4 26 35 38 25 36 27 33 32 31 See 47.01 23 22 27 34 37 39 46 30 42 19 29 43 28 44 45 26 25 33.03 24 Function Code 33.03 Master Cylinder, Servo, ABS Controller, Pipes & Hoses Dep Part Description 01 Remarks Option Part Number Qty ABS Control Module A120J6000F 1 02 ECU Kit, ABS actuator A120M6004S 1 03 HCU Kit, ABS actuator A116M0091S 1 04 Grommet, small, module to bracket sides A116J6001F 2 05 Grommet, large, module to bracket rear A116J6002F 1 06 Bolts, ABS kit A116J6003F 1 07 Bracket, ABS module mounting, RHD A116J0002F 1 07a Bracket, ABS module mounting, LHD A116J0001F 1 08 Rubber Bobbin, bracket to mount One stud, one tapped insert A082J6177F 2 09 Rubber Isolator Bush, bracket to body Two studs A082J6170F 1 10 Screw, M6 x 10, hex. hd., bobbin to bracket A075W1026Z 2 11 Washer, spring, M6, bobbin to bracket A075W4035Z 2 12 Washer, flat, M6 x 15, bobbin to bracket A075W1029Z 6 13 Nyloc Nut, M6, bobbin fix. A075W3009Z 4 14 Pipe, ABS to front RH, RHD B116J0017F 1 14a Pipe, ABS to front RH, LHD B116J0018F 1 15 Pipe, ABS to front LH, RHD B116J0016F 1 15a Pipe, ABS to front LH, LHD B116J0019F 1 16 Pipe, ABS to sill RH, RHD B116J0020F 1 16a Pipe, ABS to sill RH, LHD B116J0022F 1 17 Pipe, ABS to sill LH, RHD B116J0021F 1 Function Code: 33.03, Page: 1 Function Code 33.03 Master Cylinder, Servo, ABS Controller, Pipes & Hoses Dep Part Description 17a Remarks Option Part Number Qty Pipe, ABS to sill LH, LHD B116J0023F 1 18 Pipe, front to rear sill RH B116J0028F 1 19 Pipe, front to rear sill LH B116J0027F 1 20 Pipe, sill to flexi rear RH B120J0004F 1 21 Pipe, sill to flexi rear LH B120J0003F 1 22 Pipe, ABS to master cylinder front port, RHD B116J0030F 1 22a Pipe, ABS to master cylinder front port, LHD B116J0029F 1 23 Pipe, ABS to master cylinder rear port, RHD B116J0032F 1 23a Pipe, ABS to master cylinder rear port, LHD B116J0031F 1 24 Hose, pipe to caliper, front & rear USA Certification B082J4390F 4 25 Clip, 10mm dia. x 15 wide, hose retention Upper front, lower rear wishbones A111W6595F 4 26 Nyloc Nut, M6, thin Zn, clip to wishbone A907E6285F 4 27 Connector, brake pipes A116J6032F 4 28 Clip, double, pipes to scuttle A116W6668F 2 29 Clip, button, single, pipe to scuttle A116W6661F 2 30 Clip, single, pipe to chassis siderail A082W6457F 8 31 Clip, single, pipe to chassis rear A116W6700F 2 32 Swivel Clip, rear hoses to toe links A089W6287F 2 33 Cable Tie, rear hoses to toe links A082W6324F 2 34 Master Cylinder A116J0047H 1 35 Brake Fuid Reservoir A116J0048H 1 A082J4390F R/B LHD Cut to clear extrusion Function Code: 33.03, Page: 2 Function Code 33.03 Master Cylinder, Servo, ABS Controller, Pipes & Hoses Dep Part Description 36 Remarks Option Part Number Qty Hose, reservoir to master cylinder A116J0074H 2 37 Hose Clip, hose to spigots A116J0073H 4 38 Cable Tie, reservoir to bracket B075W6045Z 1 39 Hose, vacuum, servo to check valve A116J6038F 1 40 Hose, throttle body to check valve A120J0008K 1 41 Hose Clamp, 14mm, hose to throttle body A116K6017F 1 42 Swivel Clip, hose to heater pipe A082W6587F 6 43 Cable Tie, heater pipe to hose A082W6324F 6 44 Nut, M10 x 1.0, thin Zn, pipe to hose A075J6017Z 4 45 Washer, M10, internal shakeproof, pipe to hose A075W4049Z 4 46 Brake Servo A116J0051H 1 Function Code: 33.03, Page: 3 4 5 7 2 8 9 6 1 14 12 6 7 13 11 3 10 See 47.05 33.05 Function Code 33.05 Parking Brake Mechanism Dep Part Description 01 Remarks Option Part Number Qty Parking Brake Assembly, without hand grip A116J0015H 1 02 Hand-Grip, alloy, satin finish, parking brake lever A117U0147F 1 03 Cable, parking brake primary A120J0005H 1 04 Cable, parking brake secondary D116J0062F 1 05 Equaliser, parking brake A117J0120F 1 06 Clevis Pin, M8 x 10.5, cable fixing A111W6674F 2 07 'R' Clip, pin fixing A075W6175F 2 08 Bumper, self adhesive A111J6025F 2 09 Bumper, self adhesive A111J6027F 2 10 Screw, M8 x 25, hex. hd., lever to bracket A075W1039Z 2 11 Washer, flat, M8 x 16 x1.4, lever to bracket A075W4020Z 2 12 Switch, parking brake tell tale A116J6009H 1 13 Screw, M3 x 16, pan hd. pozi., switch to bracket A082W5110F 2 14 Nyloc Nut, M3, switch to bracket A079W3060F 2 A116J0062F R/B Function Code: 33.05, Page: 1 1 2 11 10 4 5a 3 9 5 15 14 13 7 6 9 12 8 34.01 Service Parts List Function Code 34.01 Wheels, Tyres & Valves Dep Part Description Remarks 01 Road Wheel, front, eight spoke, HP silver, 5.5J x 16 01a Road Wheel, front, eight spoke, black 5.5J x 16 01b Road Wheel, front, seven, split spoke, forged/anodised 01c Road Wheel, front, seven, split spoke, forged/painted 02 Option Part Number Qty B117G0087H 2 Optional C117G0028H 2 Not illus., 6.5 x 16, use cover, item 5 Optional A121G0013H 2 Not illus., 6.5 x 16, use cover, item 5 Optional A117G0124H 2 Tyre, front, 175/55 R16, Bridgestone Potenza 111R B117G0005L 2 02a Tyre, front, 175/55 R16, Yokohama Advan Neova AD07 USA/Canada A121G0007L 2 02b Winter Tyre, front, 195/50 R16, Pirelli W210 Snowsport Use OE type wheels Dealer fit A117G0119S 2 03 Road Wheel, rear, eight spoke, HP silver, 7.5J x 17 Use centre cover, item 5 Prior to VIN: 33180 A121G0005H 2 03a Road Wheel, rear, eight spoke, HP silver, 7.5J x 17 Use centre cover, item 5a From VIN: 33180 B121G0005H 2 03b Road Wheel, rear, eight spoke, black, 7.5J x 17 Optional A120G0023H 2 03c Road Wheel, rear, seven, split spoke, forged/anodised Not illus., 7.5 x 17, use cover, item 5 Optional A121G0015H 2 03d Road Wheel, rear, seven, split spoke, forged/painted Not illus., 7.5 x 17, use cover, item 5 Optional A120G0019H 2 04 Tyre, rear, 225/45 R17, Bridgestone Potenza 111R B117G0018L 2 04a Tyre, rear, 225/45 R17, Yokohama Advan Neova AD07 USA/Canada A121G0006L 2 04b Winter Tyre. rear, 215/45 R17, Pirelli W240 Snowsport Use OE type wheels Dealer fit A120G6001S 2 05 Wheel Centre Cover, Lotus logo Extended insert Elise, prior to VIN: 33180 A120G0021F 4 Function Code: 34.01, Page: 1 JUNE ’05 UPDATE SHOWING VIN CHANGE POINT FOR REVISED REAR WHEEL Function Code 34.01 Wheels, Tyres & Valves Dep Part Description Remarks Option Part Number Qty 05a Wheel Centre Cover, Lotus logo Flush insert Exige, + Elise from VIN: 33180 A082G4112F 4 06 Wheel Bolt, socket hd. 25mm thread B117G6000F 12 07 Wheel Bolt Adaptor, standard bolt A117G0036F 1 08 Security Wheelbolt Kit, short key B117G0043F 1 09 Tyre Valve Common A117G6007H 4 10 Road Wheel, front, eight split spoke, black 6.5 x 16 Exige A122G0007H 2 10a Road Wheel, rear, eight split spoke, black 7.5 x 17 Exige A122G0008H 2 10b Road Wheel, front, eight split spoke, silver 6.5 x 16 Exige Cup cars LOTAC05382 2 10c Road Wheel, rear, eight split spoke, silver 7.5 x 17 Exige Cup cars LOTAC05383 2 11 Tyre, front, 195/50 R16, Yokohama A048 Exige A122G0013L 2 11a Tyre, rear, 225/45 R17, Yokohama A048 Exige A117G0131L 2 12 Tyre Weld, repair canister A116G6009F 1 13 Terry Clip, cannister retaining A111W6590F 2 14 Pop Rivet, clip to bulkhead A075W6090Z 4 15 Washer, flat, clip to bulkhead A075W4084F 4 Incl. ID strip & instruction card* Function Code: 34.01, Page: 2 JUNE ’05 UPDATE SHOWING VIN CHANGE POINT FOR REVISED REAR WHEEL 1 40.00 Function Code 40.00 Engine Assemblies Dep Part Description 01 Engine assembly, undressed 01a Engine Assembly, 'short' Remarks Incl. Block, bearing panel, & moving parts Option Part Number Qty A120E6104S 1 A120E6106S 1 Function Code: 40.00, Page: 1 tl| tll J_ tl|s Service Parts List Function Code 40.01 Engine Block, Oil Pick-up Dep Part Description Remarks 01 Cylinder Block Assembly Includes integral liners, bearing panel 02 Option Part Number Qty A120E6139S 1 Bolt, panel to block A120E 10 03 Bolt, panel to block A120E6449S 1 04 Oil Strainer/Pick-up Pipe A120E6274S 1 05 Nut, flange, pick-up to panel A120E6161S 2 06 Bolt, flg, hd., pick-up to panel A120E6466S 1 07 Gasket, strainer to panel A120E6275S 1 08 Jointing Compound, panel to block A120E6474S 1 Not illustrated Function Code: 40.01, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 21 19 3 20 10 21 19 16 8 23 4 15 17 23 13 24 2 22 18 5 19 14 7 1 11 6 12 21 9 21 40.01a Service Parts List Function Code 40.01a Engine Mounts Dep Part Description 01 Remarks Option Part Number Qty Insulator, engine mounting, RH A120E6393S 1 02 Bracket, alloy, insulator to engine A120E6180S 1 03 Insulator, engine mounting, LH A120E6397S 1 04 Bracket, insulator to transmission A120E6396S 1 05 Bracket, engine mounting, front A120A0071F R/B A120A0099J 1 06 Bush, engine mounting, front A120A0098K R/B A120A0099J 1 07 Bracket, engine insulator rear B120A0085F 1 08 Insulator, engine mounting, rear A120A0035K 1 09 Bracket, engine to chassis, RH B120A0055F 1 10 Bracket, engine to chassis, LH A120A0059F 1 11 Bracket, engine to chassis, front A120A0045F 1 13 Nut, flg., bush to bracket, front A120E0102H 1 14 Bolt, flg. hd., bush to bracket, rear A120E6099H 1 14a Bolt, flg. hd., bush to bracket, front A120E0101H 1 15 Nut, flg., bush to bracket, rear A120E6100H 1 16 Bolt, flg. hd., insulator to bracket A120E6394S 2 17 Nut, flg., insulator to bracket A120E6395S 2 18 Bolt, flg. hd., bracket to engine A120E6481S 1 A120A0055F R/B Not illustrated Function Code: 40.01a, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 40.01a Engine Mounts Dep Part Description Remarks Option Part Number Qty 18a Bolt, flg. hd., bracket to engine, upper centre Not illustrated A120E6185S 1 18b Bolt, flg. hd., bracket to engine, lower Not illustrated A120E6181S 3 19 Bolt, flg. hd., insulator to chassis bracket A120E6390S 4 20 Bolt, flg. hd., bracket to transmission 21 Bolt, flg. hd., brackets to chassis 22 Bolt, flg. hd., bracket to chassis 2 23 Bolt, flg. hd., bracket to engine 4 24 Bolt, flg. hd., insulator to subframe 4 3 A116W5238F 4 Function Code: 40.01a, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 1 5 21 20 15 2 14 9 10 22 4 6 12 8 11 7 16 19 17 18 40.02 3 13 Function Code 40.02 Gaskets & Sealants, Top Overhaul Set Dep Part Description Remarks 01 Gasket Kit, cylinder head 02 Gasket, cam cover 03 Option Part Number Qty Included in item 1, 40.02a A120E6108S 1 Also see 40.07 A120E6119S 1 Gasket, cylinder head A120E6123S 1 04 Gasket, spark plug tube A120E6125S 4 05 Gasket, oil filler cap Also see 40.07 A120E6130S 1 06 Gasket, timing chain cover, large Also see 40.08a A120E6133S 1 07 Gasket, timing chain cover, small Also see 40.08a A120E6134S 1 08 Gasket, inlet manifold Also see 42.07 A120E6342S 1 09 Gasket, exhaust manifold Also see 40.21 A120E6343S 1 10 Gasket, vent tube to cam cover Also see 40.07 A120E6167S 1 11 Gasket, throttle body Also see 42.04 A120E6354S 1 12 Gasket, oil control valve housing Also see 40.05 A120E6284S 1 13 Gasket, downpipe to manifold Also see 45.01 A120E6407S 1 14 Valve Stem Oil Seal, inlet, black Also see 40.07 A120E6219S 8 15 Valve Stem Oil Seal, exhaust, green Also see 40.07 A120E6220S 8 16 Gasket, oil filter plug to head Also see 40.05 A120E6289S 1 17 'O' ring, tube to block Also see 40.15 A120E6281S 1 18 Seal, 'O' ring, pump to block Also see 40.13 A120E6300S 1 19 Oil Seal, timing cover to crankshaft A120E6459S 1 20 'O' Ring, injector Also see 42.05 A120E6357S 4 21 Insulator, injector Also see 42.05 A120E6361S 4 Function Code: 40.02, Page: 1 Function Code 40.02 Gaskets & Sealants, Top Overhaul Set Dep Part Description 22 'O' Ring, cam cover to head Remarks Option Part Number Qty A120E6127S 1 Function Code: 40.02, Page: 2 1 10 9 4 6 3 5 7 8 2 40.02a Function Code 40.02a Gaskets & Sealants, Bottom Overhaul Set Dep Part Description Remarks 01 Gasket Kit, engine overhaul 02 Option Part Number Qty Includes item 1, 40.02 A120E6107S 1 Gasket, sump plug sealing Also see 40.15 A120E6461S 1 03 Gasket, oil strainer to panel Also see 40.15 A120E6275S 1 04 Gasket, oil pump Also see 40.15 A120E6271S 1 05 Gasket, inlet housing Also see 40.13 A120E6314S 1 06 Gasket, oil separator Also see 40.07 A120E6171S 1 07 'O' Ring, exchanger to block Also see 46.03 A120E6458S 1 08 'O' Ring, filter to block Includes union, see 46.03 A120E6292S 1 09 Oil Seal, crankshaft rear A120E6138S 1 10 Gasket, coolant bypass pipe to block A120E6304S 1 Function Code: 40.02a, Page: 1 6 7 7 3 4 5 2 1 40.03 Service Parts List Function Code 40.03 Sump Assembly Dep Part Description 01 Remarks Option Part Number Qty Sump Assembly A120E6157S 1 02 Nut, flg., sump to engine A120E6161S 4 03 Bolt, hex. flg. hd., sump to engine A120E6160S 12 04 Drain Plug, sump A120E6162S 1 05 Washer, plug sealing A120E6461S 1 06 Baffle Panel, sump A120E6158S 1 07 Screw, hex. flg. hd., panel to engine A120E6164S 4 07 Jointing Compound, sump to engine A120E6474S 1 Not illustrated Function Code: 40.03, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 See 17.06 4 2 22 24 23 25 Part of head assy. 17 18 3 26 5 27 8 7 1 6 10 9 16 19 15 20 21 13 14 12 11 40.05 17 18 Service Parts List Function Code 40.05 Cylinder Head , Valves, Springs Dep Part Description Remarks 01 Cylinder Head Assembly Includes cam retaining caps 02 Option Part Number Qty A120E6109S 1 Bolt, head to block A120E6122S 10 03 Washer, flat, A120E6121S 10 04 Bolt, cam caps to head A120E6453S 20 05 Bolt, rocker shaft retention A120E6267S 10 06 Valve Spring, inlet A120E6269S 8 06a Valve Spring, exhaust A120E6268S 8 07 Valve Retainer A120E6218S 16 08 Valve Collet A120E6221S 32 09 Valve Spring seat A120E6217S 16 10 Valve Stem Oil Seal, inlet, black A120E6219S 16 10a Valve Stem Oil Seal, exhaust, green A120E6220S 16 11 Inlet Valve A120E6215S 8 12 Valve Seat Insert, inlet, standard A120E6117S 8 12a Valve Seat Insert, inlet, +0.03 A120E6112S 8 13 Valve Guide, inlet, standard A120E6110S 8 13a Valve Guide, inlet, +0.05 A120E6111S 8 14 Exhaust Valve A120E6216S 8 Function Code: 40.05, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 40.05 Cylinder Head , Valves, Springs Dep Part Description 15 Remarks Option Part Number Qty Valve Seat Insert, exhaust, standard A120E6118S 8 15a Valve Seat Insert, exhaust, +0.03 A120E6113S 8 16 Valve Guide, exhaust, standard A120E6110S 8 16a Valve Guide, exhaust, +0.05 A120E6111S 8 17 Oil Control Valve A120E6282S 2 18 Bolt, flg. hd., , valve retaining A120E6129S 2 19 Oil Filter A120E6286S 1 20 Gasket, oil filter plug to head A120E6289S 1 21 Plug, oil filter retaining A120E6288S 1 22 Oil Control Valve Housing A120E6283S 1 23 Gasket, housing to head A120E6284S 1 24 Flange Nut, housing to head A120E6287S 2 25 Screw, housing to head 26 Oil Filter A120E6285S 1 27a Shim, valve clearance, 2.000 A120E6222S As req. 27aa Shim, valve clearance, 2.020 A120E6223S As req. 27b Shim, valve clearance, 2.040 A120E6224S As req. 27bb Shim, valve clearance, 2.060 A120E6225S As req. 27c Shim, valve clearance, 2.080 A120E6226S As req. 27cc Shim, valve clearance, 2.100 A120E6227S As req. 27d Shim, valve clearance, 2.120 A120E6228S As req. Also see 17.06 3 Function Code: 40.05, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 40.05 Cylinder Head , Valves, Springs Dep Part Description Remarks Option Part Number Qty 27dd Shim, valve clearance, 2.140 A120E6229S As req. 27e Shim, valve clearance, 2.160 A120E6230S As req. 27ee Shim, valve clearance, 2.180 A120E6231S As req. 27f Shim, valve clearance, 2.200 A120E6232S As req. 27ff Shim, valve clearance, 2.220 A120E6233S As req. 27g Shim, valve clearance, 2.240 A120E6234S As req. 27gg Shim, valve clearance, 2.260 A120E6235S As req. 27h Shim, valve clearance, 2.280 A120E6236S As req. 27hh Shim, valve clearance, 2.300 A120E6237S As req. 27i Shim, valve clearance, 2.320 A120E6238S As req. 27ii Shim, valve clearance, 2.340 A120E6239S As req. 27jj Shim, valve clearance, 2.360 A120E6241S As req. 27j Shim, valve clearance, 2.380 A120E6240S As req. 27k Shim, valve clearance, 2.400 A120E6242S As req. 27kk Shim, valve clearance, 2.420 A120E6243S As req. 27l Shim, valve clearance, 2.440 A120E6244S As req. 27ll Shim, valve clearance, 2.460 A120E6245S As req. 27m Shim, valve clearance, 2.480 A120E6246S As req. 27m m Shim, valve clearance, 2.500 A120E6247S As req. 27n Shim, valve clearance, 2.520 A120E6248S As req. Function Code: 40.05, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 40.05 Cylinder Head , Valves, Springs Dep Part Number Qty 27nn Shim, valve clearance, 2.540 A120E6249S As req. 27p Shim, valve clearance, 2.560 A120E6252S As req. 27pp Shim, valve clearance, 2.580 A120E6253S As req. 27q Shim, valve clearance, 2.600 A120E6254S As req. 27qq Shim, valve clearance, 2.620 A120E6255S As req. 27r Shim, valve clearance, 2.640 A120E6256S As req. 27rr Shim, valve clearance, 2.660 A120E6257S As req. 27s Shim, valve clearance, 2.680 A120E6258S As req. 27ss Shim, valve clearance, 2.700 A120E6259S As req. 27t Shim, valve clearance, 2.720 A120E6260S As req. 27tt Shim, valve clearance, 2.740 A120E6261S As req. 27u Shim, valve clearance, 2.760 A120E6262S As req. 28o Shim, valve clearance, 2.780 A120E6250S As req. 28oo Shim, valve clearance, 2.800 A120E6251S As req. A120E0015K 1 29 Part Description Blanking Plug, unused air injection rail Remarks Option Not illustrated Function Code: 40.05, Page: 4 2005/02 UPDATE ISSUED SEPTEMBER 2005 3 19 18 4 20 13 14 11 16 13 14 17 1 15 5 19 18 28 12 24 21 2 23 22 6 29 23 See 40.08a 25 26 27 7 10 8 Supplied with camshaft item 6 9 Supplied with camshaft item 7 40.07 Function Code 40.07 Camshafts, Tappets, Cam Cover Dep Part Description 01 Remarks Option Part Number Qty Camshaft Cover A120E6012S 1 02 Gasket, cam cover A120E6119S 1 03 Bolt, cover to head A120E6131S 6 04 Screw, cover to head 05 Oil Filler Cap A120E6105S 1 06 Camshaft/Rockers, exhaust A120E6200S 1 07 Camshaft/Rockers, inlet A120E6199S 1 08 Shaft, exhaust rockers A120E6266S 1 09 Shaft, inlet rockers A120E6265S 1 10 Bolt, flg. hd., rocker shaft retention A120E6267S 10 11 Cover, spark plugs B120E0022F 1 12 Cover, fuel injection A120E0011F 1 13 Screw, M6 x 16, pan, torx hd. S/S, covers to head A117W2213F 5 14 Washer, flat, M6 x 12, covers to head A100W4127F 5 15 Hexagonal Bar, M6 x 25, plug cover to head A120W6743F 2 16 Hose, No. 2, cylinder head ventilation A120E6169S 1 17 Hose, No. 1, cylinder head ventilation A120E6168S 1 18 Hose Clip, hose No. 2 A120E6175S 2 19 Hose Clip, hose No. 1 A120E6295S 2 20 Valve Assembly, cylinder head ventilation A120E6126S 1 21 Tube Assembly, crankcase ventilation A120E6166S 1 2 A111W7170F R/B Function Code: 40.07, Page: 1 Function Code 40.07 Camshafts, Tappets, Cam Cover Dep Part Description 22 Remarks Option Part Number Qty Hose, No. 3, crankcase ventilation A120E6170S 1 23 Hose Clip, hose No. 3 A120E6177S 2 24 Flange Nut, tube assy. to cam cover A120E6179S 2 25 Casing, oil separator, crankcase ventilation A120E6165S 1 26 Stud, casing to block A120E6172S 3 27 Flange Nut, casing to block A120E6468S 3 28 Gasket, vent tube to cam cover A120E6167S 1 29 Gasket, oil separator to block A120E6171S 1 Function Code: 40.07, Page: 2 2 1 3 7 6 5 11 9 14 8 4 13 10 See 17.06 12 See 41.03 See 40.02 See 40.02 40.08a Function Code 40.08 Camshaft Drive Chain & Sprockets Dep Part Description 01 Remarks Option Part Number Qty Camshaft Drive Chain A120E6207S 1 02 Sprocket, exhaust camshaft A120E6203S 1 03 Sprocket/Valve Timing Controller Assy., inlet camshaft A120E6201S 1 04 Sprocket, drive chain, crankshaft A120E6202S 1 05 Bolt, hex. flg. hd., sprocket to inlet cam A120E6205S 1 06 Bolt, hex. flg. hd., sprocket to exhaust cam A120E6206S 1 07 Chain Tensioner Slipper A120E6209S 1 08 Bolt, hex. flg. hd., slipper to block A120E6211S 1 09 Chain Vibration Damper A120E6210S 1 10 Bolt, hex. flg. hd., damper to block 11 Drive Chain Cover A120E6132S 2 12 Bolt, hex. flg. hd., cover to engine A120E6135S 8 13 Drive Chain Tensioner A120E6208S 1 14 Flange Nut, tensioner to cover A120E6212S 2 2 Includes seal Function Code: 40.08, Page: 1 2 3 1 3 4 5 6 40.09 Function Code 40.09 Pistons, Con-rods, Liners Dep Part Description Remarks 01 Piston Assembly Incl. rings, gudgeon pin, circlips 02 Option Part Number Qty A120E6188S 4 Piston Ring Set A120E6178S 4 03 Circlip, gudgeon pin retaining A120E6189S 4 04 Con-rod A120E6190S 4 05 Con-rod Bearing Set, size 1 A120E6192S 1 05a Con-rod Bearing Set, size 2 A120E6193S 1 05b Con-rod Bearing Set, size -0.25 A120E6194S 1 06 Bolt, hex. flg. hd., cap to rod A120E6182S 8 Function Code: 40.09, Page: 1 5 3 2 4 See 40.02a 1 2 40.11 Service Parts List Function Code 40.11 Crankshaft, Bearings, Flywheel Dep Part Description 01 Remarks Option Part Number Qty Crankshaft A120E6263S 1 02 Main Bearing Set, size 1 A120E6150S 1 02a Main Bearing Set, size 2 A120E6151S As req. 02b Main Bearing Set, size 3 A120E6152S As req. 02c Main Bearing Set, size 4 A120E6153S As req. 02d Main Bearing Set, size 5 A120E6154S As req. 02e Main Bearing Set, size +0.25 A120E6155S As req. 03 Thrust Washer A120E6156S 2 04 Flywheel A120E6195S 2 05 Bolt, flywheel to crankshaft A120E6197S 8 06 Starter Gear Ring A120E6273S 1 07 Key, crankshaft A120E6192S 1 08 Pin, flywheel A120E6196S 1 Function Code: 40.11, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 1 3 2 5 7 8 9 4 6 10 40.13 Function Code 40.13 Water Pump Assembly, Thermostat Dep Part Description 01 Remarks Option Part Number Qty Water Pump Assembly A120E6298S 1 02 Seal, 'O' ring, pump to block A120E6300S 1 03 Bolt, pump to block A120E6136S 4 04 Bolt, pump to block A120E6272S 2 05 Pulley, water pump A120E6301S 1 06 Bolt, pulley to pump A120E6302S 4 07 Thermostat A120E6315S 1 08 Gasket, thermostat to cover A120E6314S 1 09 Inlet Housing, coolant to thermostat A120E6313S 1 10 Nut, cover to block A120E6468S 2 Function Code: 40.13, Page: 1 10 8 9 4 3 2 1 11 5 12 6 7 40.15 Function Code 40.15 Lubrication System Dep Part Description 01 Remarks Option Part Number Qty Oil Pump Assembly A120E6270S 1 02 Relief Valve, oil pump A120E6432S 1 03 Spring, oil pump relief valve A120E6433S 1 04 Plug, oil pump relief valve A120E6434S 1 05 Gasket, oil pump A120E6271S 1 06 Bolt, flange, oil pump to block A120E6466S 6 07 Oil Filter A120E6277S 1 08 Dipstick A120E6279S 1 09 Guide Tube, dipstick A120E6278S 1 10 Bolt, flgt. hd., guide tube fixing A120E6280S 1 11 'O' Ring, tube to block A120E6281S 1 12 Sensor, oil pressure A120E6374S 1 Function Code: 40.15, Page: 1 2 1 3 40.17 Function Code 40.17 Ignition System, Spark plugs & Plug Top Coils Dep Part Description 01 Remarks Option Part Number Qty Plug Top Coil A120E6346S 4 02 Screw, flg hd., coil to head A120E6350S 4 03 Spark Plug A120E6352S 4 Function Code: 40.17, Page: 1 1 2 6 5 14 15 3 4 13 7 12 11 8 9 40.19 10 Function Code 40.19 Alternator and Starter Motor Dep Part Description 01 Remarks Option Part Number Qty Starter Motor A120E6400S 1 02 Clutch, starter motor A120E6435S 1 03 Yoke Assembly, starter motor A120E6436S 1 04 Holder Assembly, starter motor A120E6437S 1 05 Armature Assembly, starter motor A120E6439S 1 06 Switch Assembly A120E6438S 1 07 Alternator A120E6369S 1 08 Rotor Assembly, alternator A120E6381S 1 09 Holder, rectifier, alternator A120E6392S 1 10 Holder, brush, alternator A120E6405S 1 11 Pulley, alternator A120E6417S 1 12 Nut, pulley to alternator 13 Bracket, alternator to block 14 Screw, bracket to alternator 1 15 Screw, bracket to inlet manifold 1 1 A120E6183S 1 Function Code: 40.19, Page: 1 Y5 Gz >/ /D //-/ /o( O( U lll 1 t|, Function Code 40.21 Exhaust Manifold Dep Part Description 01 Remarks Part Number Qty Exhaust Manifold A120E6331S 1 02 Stay, exhaust manifold A120E6429S 1 03 Stud, stay to engine A120E6140S 2 04 Bolt, flg. hd., stay to manifold A120E6431S 2 05 Nut, flg., stay/manifold to engine A120E6336S 4 06 Bolt, flg. hd., manifold to head A120E6335S 3 07 Stud, manifold to head A120E6120S 2 08 Gasket, exhaust manifold A120E6343S 1 Also see 40.02 Option Function Code: 40.21, Page: 1 1 2 3 40.23 Function Code 40.23 AC Compressor Dep Part Description 01 Remarks Option Part Number Qty AC Compressor AC cars A120E6414S 1 02 Clutch/Pulley Assembly, compressor AC cars A120E6415S 1 03 Bolt, flg. hd., compressor to block AC cars A120E6477S 3 Function Code: 40.23, Page: 1 3 8 2 9 1 4 7 5 41.03 6 Function Code 41.03 Auxiliary Drive Belts & Pulleys Dep Part Description 01 Remarks Option Part Number Qty Drive Belt, alternator, water pump Non AC cars A120E6418S 1 01a Drive Belt, AC compressor, alternator, water pump AC cars A120E6416S 1 02 Tensioner, drive belt A120E6316S 1 03 Spring, belt tensioner A120E6367S 1 04 Idler Assembly, drive belt A120E6403S 1 05 Pulley, crankshaft to drive belt A120E6198S 1 06 Pulley, water pump Also see 40.13 A120E6301S 1 07 Pulley, alternator Also see 40.19 A120E6417S 1 08 Flange Nut, spring to head A120E6319S 1 09 Bolt, flg. hd., spring to tensioner arm 1 Function Code: 41.03, Page: 1 2 11 9 10 1 8 7 5 4 5 See 17.06 3 6 42.01 Function Code 42.01 Airboxes, Trunking & Air Filters Dep Part Description Remarks 01 Airbox Assembly 01a Airbox Sub-assembly 02 Part Number Qty Includes element A120E6383S 1 Case only A120E6476S 1 Bracket, air cleaner mounting A120E0004F 1 03 Element, air cleaner A120E6385S 1 04 Hose, airbox to throttle body A120E6386S 1 05 Hose Clip, hose fixing A120E6055H 2 06 Air Intake Snorkel Assembly A120E0003F 1 07 Bracket, air intake snorkel mounting A120E0028H 1 08 Plastic Fastener, bracket to airbox A082W6528F 1 09 Pop Rivet, bracket to bulkhead A111W6614F 6 10 Screw, M8 x 35, hex. hd., airbox to bracket A075W1041Z 3 11 Washer, flat, M8 x 20 x 1.4, airbox to bracket A082W4165F 3 12 Hose, vacuum, 245mm, valve, vacuum switching to manifold Not illustrated A121E0008F 1 13 Blanking Plug, vacuum hose 'T' piece Not illustrated A120W6758F 1 Bonded to snorkel Option Function Code: 42.01, Page: 1 2 1 3 7 4 6 5 42.04 Function Code 42.04 Throttle Body, Mechanism & IAC Valve Dep Part Description Remarks 01 Throttle Body Includes IAC & TPS 02 Option Part Number Qty A120E6353S 1 Gasket, throttle body A120E6354S 1 03 Quadrant, throttle body A120E0019F 1 04 Gasket, IAC A120E6372S 1 05 Idle Air Control Valve (IAC) A120E6377S 1 06 Screw, flg. hd, throttle body to manifold A120E6357S 2 07 Nut, flg. hd., throttle body to manifold A120E6355S 2 Function Code: 42.04, Page: 1 2 4 1 7 6 8 5 3 42.05 Function Code 42.05 Fuel Injection System Dep Part Description 01 Remarks Option Part Number Qty Fuel Rail A120E6362S 1 02 Bolt, flg. hd., fuel rail fixing A120E6364S 2 03 Spacer, fuel rail to manifold A120E6363S 2 04 Hose Assembly, fuel rail Includes item 5 A120E6365S 1 05 Double Lock Connect, fuel feed See Service Notes: section LJ A120W6757F 1 06 Fuel Injector Includes 'O' rings A120E6479S 4 07 'O' Ring, injector A120E6357S 4 08 Insulator, injector A120E6361S 4 A120E6360S R/B Function Code: 42.05, Page: 1 12 2 5 3 13 4 7 8 1 9 6 10 11 42.07 Function Code 42.07 Inlet Manifolds, Plenum & Gaskets Dep Part Description 01 Remarks Option Part Number Qty Inlet Manifold/Plenum A120E6321S 1 02 Nut, manifold to head A120E6327S 2 03 Stud, manifold to head, upper A120E6115S 1 04 Bolt, manifold to head, short A120E6324S 2 05 Bolt, manifold to head, long A120E6325S 1 06 Bolt, manifold to head, lower A120E6326S 1 07 Stay, inlet manifold A120E6339S 1 08 Stud, stay to head A120E6329S 1 09 Nut, flg., stay to head A120E6340S 1 10 Bolt, flg. hd., stay to manifold A120E6040S 2 11 Insulator, manifold lower A120E6322S 1 12 Insulator, manifold upper A120E6323S 1 13 Gasket, inlet manifold A120E6342S 1 Function Code: 42.07, Page: 1 15 11 14 18 16 19 7 9 20 17 22 11 21 13 12 PLEASE NOTE: THE FUEL TANK & FITTINGS SHOWN IN THIS SECTION ARE FOR NON-FEDERAL MARKET VEHICLES ONLY. 6 10 PLEASE REFER TO SECTION 44.01D FOR FUEL TANK & FITTINGS FOR FEDERAL MARKETS. 23 8 2 4 5 1 8 3 24 25 24 44.01 25 12 Function Code 44.01 Fuel Tanks, Filler Dep Part Description 01 Remarks Part Number Qty Fuel Tank A120L0004H 1 02 Bracket, fuel tank support, RH B120L0040F 1 03 Bracket, fuel tank support, LH B120L0041F 1 04 Isolating Strip, tank brackets A120L0047F 2 05 Foam Support, tank sides A120L0028F 4 06 Restraint Foam, tank angled face A120L0029F 2 07 Foam Block, fuel tank retention, upper B120L0044F 2 08 Rear Restraint, tank mounting A120L0045F 2 09 Hose, fuel filler A120L0022H 1 10 Hose, fuel breather A120L0023H 1 11 Hose Clip, filler hose A117W6684F 4 12 Hose Clip, breather hose A117W6706F 4 13 Fuel Filler Neck C117L0002F 1 14 Fuel Filler Cap, less lock barrel A117L0058F 1 14a Lock Barrel & Keys, fuel cap A117L6050S 1 15 Finisher Ring, cap to clamshell B117L0024F 1 16 Gasket, rings to clamshell A117L0027F 2 17 Spacer Ring, filler to clamshell A117L0021F 1 18 Screw, M5 x 15, skt, cap hd., filler neck to clamshell A117L6033F 8 19 Screw, M5 x 10, skt. cap hd., S/S, ring to filler neck A117L3032F 2 20 Earth Braid, filler neck A079M4094F 1 Order vehicle lock set, or 14a Option Function Code: 44.01, Page: 1 Function Code 44.01 Fuel Tanks, Filler Dep Part Description 21 Remarks Option Part Number Qty Nyloc Nut, M5, braid to filler neck A075W3008F 2 22 Washer, flat, M5 x 10 x 0.8, S/S, braid to filler neck A075W1039Z 2 23 Earth Braid, fuel tank A120M0017H 1 24 Screw, M8 x 20, hex. flg. hd., brackets to chassis A120W5278F 6 25 Washer, flat, M8 x 20 x 2.5, brackets to chassis A079W4019F 4 26 Foam Pad, tank bay aperture Bonded to access panel A120L0056F 1 27 Support Pad, fuel tank front Not illustrated B120L0058F 1 A120L0058F R/B Function Code: 44.01, Page: 2 15 18 22 10 14 9 13 7 20 21 12 17 19 10 11 6 16 23 8 2 4 5 1 8 3 24 25 25 24 44.01d Service Parts List Function Code 44.01d Fuel Tanks, Filler, USA/Canada Dep Part Description 01 Fuel Tank, federal 01a Fuel Tank, federal, LEV 2 02 Remarks Part Number Qty A121L0020H 1 C121L0054H 1 Bracket, fuel tank support, RH A120L0040F 1 03 Bracket, fuel tank support, LH A120L0041F 1 04 Isolating strip, tank brackets A120L0047F 1 05 Foam Support, tank sides A120L0028F 4 06 Restraint Foam, tank angled face A120L0029F 2 07 Foam Block, fuel tank retention, upper A120L0044F 2 08 Rear Restraint, tank mounting A120L0045F 2 09 Hose, fuel filler Includes 1 hose clip A121L0009H 1 10 Hose Clip, fuel filler hose 1 off with item 9, 2 off hose to tank A120W6784F 3 11 Fuel Filler Neck, federal Includes grommet, item 12 C121L0007F 1 12 Grommet, filler neck to clamshell A121L0012H 1 13 Bowl Assembly, fuel filler A121B0048F 1 14 Cap, fuel filler A121L0035F R/B A121L6004F 1 15 Flap Assembly, fuel filler C121B0047F R/B A121B0087F 1 16 Drain Tube, fuel filler A121B0020F 1 Integral FLVV valve/roll-over valve Includes retaining strap Option '06 MY A121L0010H R/B Function Code: 44.01d, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 44.01d Fuel Tanks, Filler, USA/Canada Dep Part Description 17 Remarks Option Part Number Qty Hose Clamp, drain tube to bowl A082L6223F 1 18 Screw, M5 x 25, csk. skt. hd. S/S, flap to bowl A121W7214F 6 19 'P' Clamp, neck to backstay 'B' level backstay A121L0011H 1 19a Clip, Normaflex, neck to backstay 'C' level backstay A121W6785F 1 20 Screw, M8 x 25, hex. hd., clamp to backstay For clamp item 19 A111W1156F 1 20a Bolt, M6 x 20, flg hd., clip to backstay For clip item 19a A117W2203F 1 21 Washer, shakeproof, M8, clamp to backstay For clamp item 19 A075W4048Z 1 21a Washer, flat, M6 x 25 x 1.4, S/S, clip to backstay For clip item 19a B075W4017Z 1 22 Plastic Fastener, cap retaining strap to bowl A100W6479F 1 23 Earth Lead, fuel tank A120M0030H 1 24 Screw, M8 x 20, hex. flg. hd., brackets to chassis A120W5278F 6 25 Washer, flat, M8 x 20 x 2.5, brackets to chassis A079W4019F 4 A120M0017F R/B Function Code: 44.01d, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 o b tl| lIl - fr8 ffl + vtf Service Parts List Function Code 44.03 Fuel Pump; Filter, Pipes Dep Part Description 01 Pipe Plate Assembly 02 Fuel Pressure Regulator 03 Remarks Option Part Number Qty A120L6008S 1 A120E6413S 1 Sensor, vapour pressure A120L6014S 1 04 Filter, tank A120L6007S 1 05 Seal, pump to filter A120L6005S 1 06 Spacer, seal to filter A120L6004S 1 07 Fuel Pump A120L6002S 1 08 Filter, suction, pump A120L6001S 1 09 Clip, filter to pump A120L6003S 1 10 Rubber Cushion, pump assy. Supporting A120L6006S 1 11 Clamp Ring, fuel pump A120L0013H 1 12 Spacer Ring, fuel pump A121L0031H 1 13 Nyloc Nut, M6, pump to tank A120L0014H 8 14 Pipe, fuel feed A120L0001F 1 15 Pipe, R/O valve quick-connect to tank A120L0043F 1 16 Grommet, pipes through tank bay A121W6755F 2 17 Clip, pipe retaining A120L6012S 2 18 Gasket, pump to tank A120L6009S 1 Includes 'O' ring Euro cars Also sensor retaining Function Code: 44.03, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 44.03 Fuel Pump; Filter, Pipes Dep Part Description 18a Remarks Option Part Number Qty Gasket, pump to tank, LEV 2 '06 MY A121L0076F 1 19 Sender Unit, fuel level A120L6013S R/B A120L0020S 1 20 Access Panel, fuel pump connections A120L0046F 1 21 Screw, panel to chassis A111W7117F 4 Function Code: 44.03, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 1 4 6 5 7 2 3 10 11 8 44.05 9 12 10 Service Parts List Function Code 44.05 Charcoal Canister & Evaporative Loss System. Dep Part Description Remarks 01 Charcoal Canister Assembly Includes pipes, roll-over valve 02 Bracket, canister mounting 03 Pop Rivet, bracket to bulkhead 04 Option Part Number Qty A120L0032F 1 A120L0050F R/B B120L0050F 1 'A' level bracket A089W6297F 4 Clamp, roll-over valve A120L0052F 1 05 Screw, M5 x 16, hex. hd., clamp to bracket A075W1085F 1 06 Washer, M5, shakeproof A075W4045Z 1 07 Hose, fuel vapour feed Also on federal system Common A120E6366S 1 08 Hose Clip, fuel vapour hose to manifold Also on federal system Common A120E6462S 1 09 Bumper, bracket to bulkhead Noise insulation 'B' level bracket A116L6015F 3 10 Nyloc Nut, M6 thin, bracket fixing 'B' level bracket A907E6285F 6 11 Washer, flat, M6 x 18 x 1.0, bumper to bulkhead 'B' level bracket B082W4018F 3 12 Washer, flat, M6 x 12 x 1.6, bumper to bracket 'B' level bracket A100W4127F 3 Function Code: 44.05, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 28 29 11 35 10 6 30 26 25 32 33 34 12 27 14 16 13 8 21 31 1 15 20 7 23 3 5 19 24 18 17 38 22 37 36 44.05c 2 4 Service Parts List Function Code 44.05c Charcoal Canister & Evap. Loss System, USA/Canada Dep Part Description 01 Remarks Option Part Number Qty Evaporative Canister, charcoal A121L0002F 1 02 Bracket, canister mounting A121L0003F 1 03 Bracket Clamping, canister B121L0038F 1 04 Screw, M6 x 16, hex. hd., clamp to bracket A075W1036Z 1 05 Washer, M6, shakeproof, clamp to bracket A075W4046Z 1 06 Canister Close Valve A121L0004F 1 07 Fill Level Vent Valve A082L6229F 1 08 Plate, FLVV valve A121L0024H 1 09 Pipe, purge valve to inlet manifold B121L0013F 1 10 Pipe Assembly, FLVV valve to canister A121L0015F 1 11 Hose, close valve to canister B121L0006F 1 11a Hose, close valve to canister, LEV 2 A121L0051F 1 12 Hose Clamp, stepless, hose, close valve to canister A121W6774F 2 13 Pipe Assembly, canister to purge solenoid valve A121L0036F 1 14 Hose, FLVV to 'T' piece B121L0021F 1 15 Hose Clamp, stepless, hose, FLVV to 'T' piece A121W6773F 2 16 Roll-over Valve Pipes & Hoses Assembly B121L0040F 1 17 Clamp, roll-over valve to fuel tank A120L0052F 1 For hose to manifold see 44.05 '06 MY Includes clamp, item 17 Function Code: 44.05c, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 44.05c Charcoal Canister & Evap. Loss System, USA/Canada Dep Part Description 18 Remarks Option Part Number Qty Screw, M5 x 16, hex. hd., clamp to tank A075W1085Z 1 19 Washer, M5, shakeproof, clamp to tank A075W4045Z 1 20 Nyloc Nut, M5, clamp to tank A075W3008Z 1 21 Purge Solenoid Valve A082L6225F 1 22 Bracket, purge valve mounting C121L0023F 1 23 Screw, M6 x 16, hex. hd., bracket to manifold boss A075W1028Z 1 24 Washer, flat, M6 x 20 x 2.5, bracket to manifold boss A075W4016Z 1 25 Cable Tie, FLVV pipe to filler hose A116W6691F 1 26 Swivel Clip, FLVV pipe to filler hose A082W6587F 1 27 Cable Tie, FLVV pipe to filler hose A075W6038Z 1 28 Spirenut, No. 6, close valve to bracket A075W6014Z 1 29 Screw, No. 6 x 0.25", pan hd. pozi., close valve to bracket A121W5283F 1 30 Pipe Assembly, pump to tank, LEV 2 '06 MY A121L0060F 1 31 Bracket, connector retaining '06 MY A121L0074F 1 32 Nyloc Nut, M6, bracket to tank '06 MY A075W3009Z 2 33 Washer, flat, M6, S/S, bracket to tank '06 MY A082W4133F 2 34 Washer, flat, M8, S/S, bracket to tank '06 MY A111W4176F 2 35 Pipe Assembly, FLVV valve to canister, LEV 2 '06 MY A121L0058F 1 36 Evaporative Canister, charcoal, LEV 2, 1.85L '06 MY A121L6005F 1 37 Bracket, canister mounting, LEV 2 '06 MY A121L0050F 1 38 Nut, M6, flg., canister mounting, LEV 2 '06 MY A117W3180F 1 Replaces items 25 & 26 Function Code: 44.05c, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 U ul J_ UE Function Code 45.01 Exhaust System Dep Part Description Remarks Option Part Number Qty 01 Silencer Assembly, Euro Includes clamp Europe/ROW C120S0003F 1 01a Silencer Assembly, Federal Includes clamp USA/canada B121S0002F 1 02 Catalyst/Downpipe Assembly Common B120S0002F 1 03 Exhaust Mounting, silicon, exhaust to subframe A111S0071F 4 04 Clip, exhaust hanger A117S0049F 4 05 Bolt, M8 x 35, flg. hex hd. A117W5249F 8 06 Nut, M8, mount to bracket A075W3021Z 4 07 Bracket, silencer to subframe, RH A120A0110F 1 08 Bracket, silencer to subframe, LH A120A0111F 1 09 Screw, M6 x 10, hex. hd., bracket to subframe A111E6007F 2 10 Washer, flat, M6 x 25, bracket to subframe B075W4017Z 2 11 Gasket, downpipe to manifold A120E6407S 1 12 Bolt, flg. hex. hd., downpipe to manifold A120E6409S 2 13 Spring, downpipe to manifold A120E6408S 2 14 Edge Finisher, bracket/subframe A075V6020V 300mm Function Code: 45.01, Page: 1 15 26 1 28 27 14 11 8 30 3 13 29 4 12 2 24 23 10 19 7 16 9 17 5 6 45.05 25 18 20 21 22 Service Parts List Function Code 45.05 Heatshields Dep Part Description 01 Heatshield, bulkhead 01a Heatshield, bulkhead, LEV 2 02 Remarks Part Number Qty B120B0065F 1 '06 MY A120B0138F 1 Heatshield, bootbox Elise B120S0005F 1 02a Heatshield, bootbox Exige A122S0004F 1 03 Heatshield, striker assembly Elise, A120B0012F R/B B120B0012F 1 04 Heatshield Assembly, muffler E120S0024F R/B F120S0024F 1 05 Heatshield, muffler 'U' bend upper D120S0029F 1 06 Heatshield, muffler 'U' bend lower D120S0030F 1 07 Heatshield/NVH Pad, tank bay closure A121L0046F 1 08 Heatshield, rear engine mount A120S0010F 1 09 Heatshield, boot floor insulation B120V0009F 1 10 Heatshield, rear license plate A117S0041F 1 11 Heatshield, exhaust manifold, upper A120E6332S 1 12 Heatshield, exhaust manifold, lower A120E6333S 1 13 Heatshield, tailgate latch assembly Exige C122S0001F 1 14 Heatshield, latchrail/bulkhead, LH Foiled foam mat, self adhesive Exige A122S0005F 1 15 Heatshield, latchrail/bulkhead, RH Foiled foam mat, self adhesive Exige A122S0006F 1 16 Pop Rivet, blind, bootbox heatshield fixing A111W6614F 5 Part of striker/lift assembly Option Function Code: 45.05, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 45.05 Heatshields Dep Part Description 17 Remarks Option Part Number Qty Washer, flat, M5 x 25, black, bootbox heatshield fixng A082W4098F 10 18 Screw, M6, hex. flg. hd., muffler heatshield fixing A111E6007F 6 19 Washer, flat, M6 x 25, muffler heatshield fixing B075W4017Z 3 20 Screw, M6 x 10, hex. hd., heatshield to 'U' bend A075W1026Z 4 21 Washer, spring, M6, heatshield to 'U' bend A075W4035Z 4 22 Washer, flat, M6 x 25, heatshield to 'U' bend B075W4017Z 4 23 Screw, M6 x 12, hex. flg. hd., eng. mount heatshield fixing A111E6007F 2 24 Washer, flat, M6 x 25, engine mount heatshield fixing A075W4017Z 2 25 Pop Rivet, license plate heatshield fixing A089W6297F 2 26 Screw, M6 x 16, hex. hd., heatshield to latch Exige A075W1028Z 3 27 Washer, flat M6 x 18 x 1, heatshield to latch Exige B082W4018F 3 28 Bolt, manifold heatshield upper fixing A120E6482S 4 29 Bolt, manifold heatshield lower fixing A120E6483S 4 30 Heatshield Closure Plate, RH B120S0028H 1 Part of item 4 Function Code: 45.05, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 19 41 21 22 20 8 55 40 14 25 42 42 15 30 26 41 45 43 43 18 43 30 29 40 12 16 46 13 23 44 24 38 53 11 7 34 10 36 38 43 52 25 See 18.05 40 37 27 29 39 17 9 40 38 54 5 35 31 32 2 36 4 7 39 51 32 33 34 3 48 47 46.01 4 6 Function Code 46.01 Engine Cooling System & Fan Dep Part Description 01 Remarks Option Part Number Qty Radiator Housing Elise B120B0093F 1 01a Radiator Housing Exige A122B0111F 1 02 Radiator A117K0021F 1 03 Bracket, fans to radiator A117K0025F 2 04 Radiator Cooling Fan A111M6070F 2 05 Hose, pipe to radiator, RH A117K0008F 1 06 Hose, pipe to radiator, LH A117K0015F 1 07 Pipe, chassis water rail A116K0018F 2 08 Hose, engine inlet B120K0001F 1 09 Hose, outlet to chassis pipe B116K0016F 1 10 Hose, engine outlet B120K0005F 1 11 Hose, header tank to water pump A120K0007F 1 12 Hose, engine to re-circ pump B120K0002F 1 13 Hose Assembly, return pipe to engine Also see 18.05, includes bleed D120K0004F 1 13a Hose, return pipe to engine Use with item 54 E120K0004F 1 14 Hose header tank to engine B120K0006F 1 15 Header Tank Assembly A120K6005S 1 16 Blanking Hose, header tank de-gas vent A120K0008F 1 17 Bracket, header tank mounting D120K0009F 1 18 Recirculation Pump A117K0013F 1 19 Shroud, radiator, RH A120B0046F 1 Includes bleed valve Elise Function Code: 46.01, Page: 1 Function Code 46.01 Engine Cooling System & Fan Dep Part Description 20 Shroud, radiator, LH 21 Remarks Option Part Number Qty Elise A120B0047F 1 Screw, M5 x 16, skt. button hd., shroud to housing A111W7156F 2 22 Washer, flat, M5 x 19 x 1.4, s/s, black, shroud to housing A082W4107F 2 23 Screw, M5 x 20, skt. button hd., hsg. to crash structure A082W7173F 6 24 Washer, flat, M5, housing to crash structure A340W4183F 6 25 Spirenut, M5, shroud to housing/housing to crash structure A117W6697F 8 26 Spreader Plate, rear bracket to housing A117P0117F 2 27 Bracket, radiator to housing rear A117K0006F 2 28 Spreader Plate, front bracket to housing A117P0102F 2 29 Bracket, radiator to housing front A117K0005F 2 30 Bolt, M8 x 16, flg. hd.,brackets to radiator/housing A117W2202F 18 31 Screw, M6 x 16, hex. hd., bracket to radiator A075W1028Z 8 32 Washer, flat, M6 x 12, bracket to radiator A075W4013Z 16 33 Nyloc Nut, M6 A075W3009Z 8 34 Foam, condenser to housing sides RH remove pre-cut slots C117B0282F 2 35 Foam, condenser to housing rear edge Three sections A117B0446F 1 36 Grommet, pipe through chassis front A111K6006F 2 37 Grommet, hose through chassis rear A082K6022F 2 38 Seal, pipe to chassis A111A0033F 4 39 Hose Clip, hose to rad. spigots/chassis pipes A075M6145F 4 40 Hose Clamp, 40mm, hose to pipe rear A116K6015F 4 AC cars Function Code: 46.01, Page: 2 Function Code 46.01 Engine Cooling System & Fan Dep Part Description 41 Remarks Option Part Number Qty Hose Clamp, 44mm, hose to engine A116K6014F 1 42 Hose Clamp, 15.7mm, hose to engine/header tank A120W6738F 2 43 Hose Clamp, 27mm, heater feed/return hoses A116K6016F 3 44 Hose Clamp, 17.7mm, hose to header tank A120W6739F 2 45 Hose Clamp, 26mm, hose to engine A120W6776F 1 46 Hose, header tank overflow 47 Nyloc Nut, M5, fan to bracket A075W3008Z 4 48 Washer, flat, M5 x 18 x 1.4, fan to bracket B075W4009Z 4 49 Screw, M8 x 20, flg. hd., bracket to engine mount A116W5246F 1 50 Cap, header tank A120E6341S 1 51 Shroud, radiator, one piece B122K0001K 1 52 Screw, M8 x 20, hex. flg. hd., bracket to engine mount A116W5246F 1 53 Hose Clip, 19mm, bleed hose to 'T' piece A116E6034F 1 54 Hose, header tank bleeding Use with item 13a A120K0022F 1 55 Captive Nut, M8, big hd., housing to clamshell Bonded to housing A111W6592F 2 56 Pipe, coolant bypass Not illustrated A120E6306S 1 57 Hose, coolant bypass Not illustrated A120E6309S 1 58 Hose, coolant bypass to NRV Not illustrated A120E6307S 1 59 Hose, NRV to throttle body Not illustrated A120E6308S 1 1 Exige Function Code: 46.01, Page: 3 !t I (\ 0 / F ot-€A , / , ,z\. ' \ \ \ / rv< ,J4Z.'J \ , ta\ >=\ -/'Q \ tr O) FOR FULL EXPLANATION PLEASE REFER TO TECHNICAL SERVICE BULLETIN 2005/05 , SINGLE OIL COOLER FITTED TO 05’ MODEL YEAR ELISE FROM VIN SERIAL NUMBER 32444 F @ k). l* (\I G7\ 1 \ ) ) fl nnrffi\h ,,6 "'ruU-.ltlY o m t, tll J." q l:.| Service Parts List Function Code 46.03 Oil Cooler & Pipes Dep Part Description 01 Remarks Option Part Number Qty Oil Cooler, RH A120K0020F 1 02 Oil Cooler, LH A120K0021F 1 03 Nyloc Nut, M8, cooler to bracket A907E6284F 4 04 Washer, flat, M8 x 20.5 x 1.4, cooler to bracket A082W4165F 4 05 Bracket, oil cooler mounting A120A0079F 2 06 Screw, M8 x 20, hex hd., bracket to nutplate A075W1038Z 4 07 Washer, spring, M8, bracket to nutplate A075W4036Z 4 08 Washer, flat, M8 x 16.6 x 1.4, bracket to nutplate A075W4020Z 4 09 Nutplate, bracket to crash structure, RH A120K0017F 1 10 Bracket, siren mounting Also nutplate for LH bracket A120K0018F 1 11 Hose, oil cooler to sandwich plate, LH Replaces common hose C120K0011F R/B A120K0027F 1 11a Hose, oil cooler to sandwich plate, RH Replaces common hose C120K0011F R/B A120K0028F 1 12 Hose oil cooler RH to oil cooler LH A120K0012F 1 13 Sandwich Plate & Thermostat Assy. A120K6001F 1 14 Seal, adaptor to oil filter housing A120K6002H 1 15 Duct, oil cooler, RH Elise A120B0090F 1 15a Duct, oil cooler, RH Exige A122B0194F 1 16 Duct, oil cooler, LH Elise A120B0091F 1 Function Code: 46.03, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 46.03 Oil Cooler & Pipes Dep Part Description Remarks Option Part Number Qty 16b Duct, oil cooler, LH Exige A122B0195F 1 17 Pop Rivet, duct to radiator housing A089W6297F 6 18 Clip, oil cooler hose A120W6760F 9 19 Grommet, hose through sill front A082H6046F 2 20 Connector, feed & return hoses A120E0017F 1 21 Clip, oil cooler hose to heater hose A116W6692F 2 22 Bracket, oil cooler replacement, RH Single oil cooler cars A120K0024F 1 23 Heat Exchanger, oil/water, engine mounted Non oil cooler cars A120E6293S 1 24 Hose Assembly, coolant feed/return Non oil cooler cars A120E6294S 1 25 Hose Clip, hose to spigots Non oil cooler cars A120E6295S 4 26 'O' Ring, exchanger to block Non oil cooler cars A120E6458S 1 27 Union, filter to exchanger Non oil cooler cars A120E6292S 1 Bonded inside sills Oil cooler cars Includes 'O' ring, item 25 Includes 'O' ring Function Code: 46.03, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 18 16 17 19 20 21 14 13 22 10 11 15 12 23 1 9 2 8 7 3 4 5 6 47.01 Function Code 47.01 Clutch & Release Mechanism Dep Part Description 01 Remarks Option Part Number Qty Clutch Release Master Cylinder A116Q0001H 1 02 Quick Connector, pipe to master cylinder A116Q6001F 1 03 Pipe, clutch, front, RHD B120Q0002F 1 03a Pipe, clutch, front, LHD B120Q0001F 1 04 Grommet, front pipe A075U6043Z 1 05 Bracket, clutch hose to chassis A120Q0005F 1 06 Pop Rivet, bracket to chassis A111W6613F 2 07 Bracket, clutch hose to transmission A120Q0004F 1 08 Hose, pipe front to pipe rear A116Q0016F 1 09 Pipe, clutch, rear A120Q0003F 1 10 Clutch Release Slave Cylinder A120Q6011S 1 10a Cylinder Repair Kit, clutch release A120Q6009S 1 11 Push Rod, release slave cylinder A120Q6012S 1 12 Boot, release slave cylinder A120Q6013S 1 13 Bleed Plug, release slave cylinder A120Q6015S 1 14 Cap, bleed plug A120Q6014S 1 15 Bracket, release slave cylinder A120Q6016S 1 16 Clutch Driven Plate A120Q6003S 1 17 Clutch Cover Assembly A120Q6001S 1 18 Bolt, hex. flg. hd., cover to flywheel A120Q6002S 6 19 Clutch Release Bearing A120Q6007S 1 Function Code: 47.01, Page: 1 Function Code 47.01 Clutch & Release Mechanism Dep Part Description 20 Remarks Option Part Number Qty Clip, clutch release bearing hub A120Q6008S 1 21 Clutch Release Fork A120Q6006S 1 22 Support, release fork A120Q6010S 1 23 Boot, clutch release fork A120Q6005S 1 Function Code: 47.01, Page: 2 34 15 5 10 33 17 2 6 16 15 9 8 7 18 19 11 12 13 14 3 21 35 20 4 23 22 24 1 25 26 27 29 28 31 30 47.03 32 Function Code 47.03 Transmission Assembly Dep Part Description 01 Remarks Option Part Number Qty Transmission Assembly A120F6001SF 1 02 Clutch Housing A120F6022S 1 03 Transmission Casing A120F6034S 1 04 Transmission End Cover A120F6048S 1 05 Reciever, transmission case A120F6028S 1 06 Bolt, receiver to casing A120F6027S 1 07 Pipe, oil receiver 1 A120F6039S 1 08 Bolt, pipe to casing A120F6040S 1 09 Pipe, oil receiver 2 A120F6050S 1 10 Bolt, pipe to casing A120F6040S 1 11 Plug, casing upper A120F6166S 1 12 Switch, reverse lamp A120F6239S 1 13 Sealing Washer, switch 14 Ball Assembly, locking A120F6161S 1 15 Bolt, M12 x 55, flg. hd., clutch housing to engine A120F6246S 2 16 Cover, speedo drive A120F6244S 1 17 Bolt, cover to casing A120F6245S 1 18 'O' Ring, cover to casing A120F6254S 1 19 Gaiter, clutch release arm A120Q6005S 1 20 Magnet, swarf attraction A120F6030S 1 21 Dowel, clutch housing to casing A120E6196S 1 1 Function Code: 47.03, Page: 1 Function Code 47.03 Transmission Assembly Dep Part Description 22 Remarks Option Part Number Qty Plug, casing lower A120F6166S 1 23 Sealing Washer A120F6043S 1 24 Plug A120F6049S 1 25 Sealing Washer A120F6043S 1 26 Bolt, casing to clutch housing A120F6031S 13 27 Dowel, casing to rear cover A120F6046S 1 28 Plug, gearbox oil filler A120F6049S 1 29 Sealing Washer A120F6043S 1 30 Plug, gearbox oil drain A120F6041S 1 31 Sealing Washer, drain plug A120F6043S 1 32 Bolt, end cover to casing A120F6047F 9 33 Bolt, M10 x 65, hex. hd., clutch housing to engine/starter With wavy washer A120E6402S 2 34 Bolt, M10 x 55, hex. hd., engine to clutch housing With flat washer A120E6247S 2 35 Bolt, M10 x 30, flg. hd., sump to clutch housing A120E6380S 2 36 Gasket Set, transmission overhaul Not illustrated A120F6002S 1 37 Jointing Compound, transmission end cover Not illustrated A120F6260S 1 Function Code: 47.03, Page: 2 4 22 23 7 24 13 12 14 11 27 10 5 16 17 25 2 21 26 15 6 3 8 1 47.05 18 19 20 9 Service Parts List Function Code 47.05 Gearchange Mechanism, External Dep Part Description Remarks Option Part Number Qty 01 Gearshift/Parking Brake Assembly, RHD For parking brake see 33.05 D120F0004F R/B E120F0004F 1 01a Gearshift/Parking Brake Assembly, LHD For parking brake see 33.05 D120F0001F R/B E120F0001F 1 02 Cable, gearshift A120F0003H 1 03 Cable, crossgate A120F0002H 1 04 Gearknob, six speed, round lever With grub screw C120U0012F 1 04a Gearknob, six speed, hexagonal lever With grub screw B120U0012F 1 04b Knurl Point Grub Screw, M5 x 16, knob to lever A120W5292F 1 05 Lift Tube, reverse select, round lever B120U0017F 1 05a Lift Tube, reverse select, hexagonal lever A120U0017F 1 06 Lift Tube Adaptor, lift tube to cable, round lever A120F6259S 1 06a Lift Tube Adaptor, lift tube to cable, hexagonal lever A120F6257S 1 07 Retaining Washer, lift tube to adaptor, round lever B120W6770F 1 07a Retaining Washer, lift tube to adaptor, hexagonal lever A120W6770F 1 08 Cable, reverse select A120F6258S 1 09 Abutment, tranmission casing A120F6241S 1 10 'C' Clip, cables to abutment A116F0013F 2 11 'R' Clip, cables to levers A075W6175F 2 12 Crank Assembly, shift & select A120F6167S 1 A120U0012F R/B Function Code: 47.05, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.05 Gearchange Mechanism, External Dep Part Description 13 Remarks Option Part Number Qty Control Shaft, select A120F6168S 1 14 Dust Cover, crank pivot A120F6170S 1 15 Crank Assembly, shift A120F6169S 1 16 Dust Cover, crank to bracket A120F6172S 2 17 Bush, crank pivot A120F6174S 2 18 Washer Plate, crank pivot A120F6173S 1 19 Nut, crank to shaft A120F6175S 1 19a Washer, spring, crank to shaft A120F6176S 1 20 Dust Cover, crank pivot A120F6171S 1 21 Dust Cover, crank to selector A120F6177S 1 22 Gear Lever, round section, RHD Service replacement, use tool item 29 A120F0008S 1 22a Gear Lever, round section, LHD Service replacement, use tool item 29 A120F0009S 1 23 Lever, control shift A120F6196S 1 24 Pin, lever clamping A120F6195S 1 25 Washer, wavy, lever to nut A120F6176S 1 26 Nut, flange, lever clamping A120F6175S 1 27 Nut, flange, lever to control shaft balljoint A120F6194S 1 28 Screw, M8 x 20, skt. button hd., assembly rear to chassis A075W7022F 2 Not illustrated Function Code: 47.05, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.05 Gearchange Mechanism, External Dep Part Description Remarks 29 Tool, gear lever bush guide Not illus. For gear lever replacement: See Service Notes section FJ Option Part Number Qty A120U0054S 1 Function Code: 47.05, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 15 16 14 2 13 10 12 4 1 9 7 3 5 8 24 9 6 11 23 25 27 17 28 22 19 20 30 31 32 33 29 26 34 35 30 31 32 33 30 31 32 38 29 33 36 29 39 37 42 41 40 38 47.06 21 18 Service Parts List Function Code 47.06 Gear Selector Mechanism, Internal Dep Part Description 01 Remarks Option Part Number Qty Seal, outer, shaft to casing A120F6036S 1 02 Dust Boot, inner, shaft to casing A120F6197S 1 03 Bush, select/shift shaft A120F6256S 1 04 Bearing, needle roller A120F6037S 1 05 Retainer, 'E' ring, spring seat A120F6186S 1 06 Seat, select spring no.2 A120F6183S 1 07 Spring, select return, no. 2 A120F6185S 1 08 Lever, shift inner no.2 A120F6180S 1 09 Pin, slotted spring A120F6183S 2 10 Plate, shift interlock A120F6182S 1 11 Lever, shift inner no.1 A120F6179S 1 12 Seat, select spring no.1 A120F6187S 1 13 Spring, selec return no.1 A120F6185S 1 14 Plug, reverse restrict pin A120F6201S 1 15 Ball Assembly, lock no.1 A120F6161S 1 16 Plug, transmission breather A120F6038S 1 17 Shaft, shift & select A120F6181S 1 18 Cover Assembly, control shaft A120F6188S 1 Function Code: 47.06, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.06 Gear Selector Mechanism, Internal Dep Part Description Remarks 19 Snap Ring, support to case 20 Option Part Number Qty Not used on Lotus A120F6192S 1 Seat, select spring no.3 Not used on Lotus A120F9189S 1 21 Spring, shift/select shaft Not used on Lotus A120F6193S 1 22 Bush, select/shift shaft A120F6255S 1 23 Gasket, cover to case A120F6190S 1 24 Bolt, hex. flg. hd., cover to case A120F6159S 4 25 Reverse Shift Arm/Bracket Assembly A120F6152S 1 26 Screw, bracket to casing A120F6153S 2 27 Reverse Shift Fork A120F6200S 1 28 Shaft, gear shift fork, No. 3 A120F6199S 1 29 Snap ring, external, shift shafts A120F6158S 3 30 Plug, shift dent assy. A120F6163S 3 31 Spring Seat, shift detent A120F6162S 3 32 Spring, shift detent A120F6165S 3 33 Detent Ball A120F6164S 3 34 Gear Shift Fork, No. 3 A120F6202S 1 35 Screw, fork to shaft A120F6157S 1 36 Shaft, gear shift fork, No. 1 A120F6151S 1 37 Gear Shift Fork, No. 1 A120F6154S 1 38 Bolt, hex, hd., forks to shaft A120F6157S 2 39 Shaft, gear shift fork, No. 2 A120F6198S 1 Function Code: 47.06, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.06 Gear Selector Mechanism, Internal Dep Part Description 40 Remarks Option Part Number Qty Gear Shift Fork, No. 2 A120F6155S 1 41 Gear Shift Head, No. 1 A120F6156S 1 42 Bolt, hex, hd., head to shaft A120F6157S 1 Function Code: 47.06, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 2 1 5 6 3 7 4 8 9 10 11 12 15 30 18 31 19 16 13 14 20 32 17 21 22 33 23 34 49 50 24 35 25 36 27 37 47 48 45 54 55 67 69 68 56 46 57 55 58 52 59 60 61 62 47.07 28 44 52 53 65 66 40 41 42 43 38 39 51 26 63 64 29 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 01 Remarks Option Part Number Qty Cover, output shaft A120F6029S 1 02 Bearing, roller, output shaft, front A120F6007S 1 03 Plate, bearing retention A120F6026S 1 04 Bolt, plate to casing A120F6027S 1 05 Ball, output shaft A120F6078S 1 06 Output Shaft A120F6203S 1 07 Thrust Washer, 1st gear A120F6077S 1 08 Bearing, needle roller, 1st gear A120F6016S 1 09 1st Gear, driven A120F6141S 1 10 Synchro Ring, 1st gear A120F6075S 1 11 Reverse Gear, driven A120F6071S 1 12 Synchro Hub, no 1 A120F6072S 1 13 Spring, synchro key A120F6075S 3 14 Synchro Key A120F6073S 3 15 Synchro Ring, 2nd gear A120F6075S 1 16 Snap Ring, hub to shaft, A, 2.50mm A120F6082S 1 16a Snap Ring, hub to shaft, B, 2.56mm A120F6083S 1 16b Snap Ring, hub to shaft, C, 2.62mm A120F6084S 1 16c Snap Ring, hub to shaft, D, 2.68mm A120F6085S 1 16d Snap Ring, hub to shaft, E, 2.74mm A120F6086S 1 16e Snap Ring, hub to shaft, F, 2.80mm A120F6087S 1 Function Code: 47.07, Page: 1 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 17 Remarks Option Part Number Qty Spacer, 2nd gear bearing A120F6014S 1 18 Bearing, needle roller, 2nd gear A120F6013S 1 19 2nd Gear, driven A120F6142S 1 20 3rd Gear, driven A120F6144S 1 21 Spacer, output shaft A120F6079S 1 22 4th Gear, driven A120F6146S 1 23 Bearing, ball, output shaft centre A120F6008s 1 24 Snap Ring, bearing retention A120F6081S 1 25 5th Gear, driven A120f6148S 1 26 Spacer, output gear A120F6080S 1 27 6th Gear, driven A120F6150S 1 28 Bearing, ball, output shaft rear A120F6009S 1 29 Snap Ring, bearing to shaft, rear, B, 2.31mm A120F6121S 1 29a Snap Ring, bearing to shaft, rear, C, 2.37mm A120F6122S 1 29b Snap Ring, bearing to shaft, rear, D, 2.43mm A120F6123S 1 29c Snap Ring, bearing to shaft, rear, E, 2.49mm A120F6124S 1 29d Snap Ring, bearing to shaft, rear, F, 2.55mm A120F6125S 1 29e Snap Ring, bearing to shaft, rear, G, 2.61mm A120F6126S 1 29f Snap Ring, bearing to shaft, rear, H, 2.67mm A120F6127S 1 29g Snap Ring, bearing to shaft, rear, J, 2.73mm A120F6128S 1 29h Snap Ring, bearing to shaft, rear, K, 2.79mm A120F6129S 1 Function Code: 47.07, Page: 2 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 29i Remarks Option Part Number Qty Snap Ring, bearing to shaft, rear, L, 2.85mm A120F6130S 1 29j Snap Ring, bearing to shaft, rear, M, 2.91mm A120F6131S 1 30 Oil Seal, input shaft, front A120F6023S 1 31 Bearing, roller, input shaft, front A120F6004S 1 32 Input Shaft A120F6140S 1 33 Bearing, needle roller, 3rd gear A120F6015S 1 34 Reverse Gear A120F6071S 1 35 Synchro Ring, 3rd gear A120F6056S 1 36 Synchro Sleeve, no. 2 A120F6053S 1 37 Synchro Hub, no. 2 A120F6052S 1 38 Spring, synchro key A120F6076S 3 39 Synchro Key A120F6054S 3 40 Synchro Ring, 4th gear A120F6074S 1 41 Snap Ring, hub to shaft, 0, 2.30mm A120F6058S 1 41a Snap Ring, hub to shaft, 1, 2.36mm A120F6059S 1 41b Snap Ring, hub to shaft, 2, 2.42mm A120F6060S 1 41c Snap Ring, hub to shaft, 3, 2.48mm A120F6061S 1 41d Snap Ring, hub to shaft, 4, 2.54mm A120F6062S 1 41e Snap Ring, hub to shaft, 5, 2.60mm A120F6063S 1 42 Spacer A120F6017S 1 43 Bearing, needle roller, 4th gear A120F6012S 1 Function Code: 47.07, Page: 3 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 44 Remarks Option Part Number Qty 4th Gear A120F6145S 1 45 Bearing, ball, input shaft, centre A120F6009S 1 46 Snap Ring, bearing to shaft, A, 2.29mm A120F6064S 1 46 Snap Ring, bearing to shaft, B, 2.35mm A120F6065S 1 46a Snap Ring, bearing to shaft, C, 2.41mm A120F6066S 1 46b Snap Ring, ibearing to shaft, D, 2.47mm A120F6067S 1 46c Snap Ring, bearing to shaft, E, 2.53mm A120F6068S 1 46d Snap Ring, bearing to shaft, F, 2.59mm A120F6069S 1 47 Snap Ring, bearing to casing A120F6070S 1 48 Retainer, input shaft rear bearing A120F6044S 1 49 Bolt, retainer to casing A120F6045S 5 50 Bearing, needle roller, 5th gear A120F6018S 1 51 Spacer, 5th gear bearing A120F6147S 1 52 Snap Ring, hub to shaft, A, 1.75mm A120F6100S 1 52a Snap Ring, hub to shaft, B, 1.80mm A120F6101S 1 52b Snap Ring, hub to shaft, C, 1.85mm A120F6102S 1 52c Snap Ring, hub to shaft, D, 1.90mm A120F6103S 1 52d Snap Ring, hub to shaft, E, 1.95mm A120F6104S 1 52f Snap Ring, hub to shaft, F, 2.00mm A120F6105S 1 52g Snap Ring, hub to shaft, G, 2.05mm A120F6106S 1 52h Snap Ring, hub to shaft, H, 2.10mm A120F6107S 1 Function Code: 47.07, Page: 4 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 52i Remarks Option Part Number Qty Snap Ring, hub to shaft, J, 2.15mm A120F6108S 1 53 5th Gear A120F6147S 1 54 Synchro Ring, 5th gear A120F6093S 1 55 Spring, synchro key A120F6095S 3 56 Synchro Key A120F6097S 3 57 Synchro Hub, no. 3 A120F6096S 1 58 Synchro Sleeve A120F6098S 1 59 Synchro Ring, 6th gear A120F6093S 1 60 Spacer, bearing, 6th gear A120F6021S 1 61 Bearing, needle roller, 6th gear A120F6020S 1 62 6th gear A120F6149S 1 63 Bearing, ball, input shaft, rear A120F6006S 1 64 Snap Ring, bearing to shaft rear, A, 1.70mm A120F6109S 1 64a Snap Ring, bearing to shaft rear, B, 1.75mm A120F6110S 1 64b Snap Ring, bearing to shaft rear, C, 1.80mm A120F6111S 1 64c Snap Ring, bearing to shaft rear, D, 1.85mm A120F6112S 1 64d Snap Ring, bearing to shaft rear, E, 1.90mm A120F6113S 1 64e Snap Ring, bearing to shaft rear, F, 1.95mm A120F6114S 1 64f Snap Ring, bearing to shaft rear, G, 2.00mm A120F6115S 1 64g Snap Ring, bearing to shaft rear, H, 2.05mm A120F6116S 1 64h Snap Ring, bearing to shaft rear, J, 2.10mm A120F6117S 1 Function Code: 47.07, Page: 5 Function Code 47.07 Gears, Shafts & Bearings Dep Part Description 64i Remarks Option Part Number Qty Snap Ring, bearing to shaft rear, K, 2.15mm A120F6118S 1 64j Snap Ring, bearing to shaft rear, L, 2.20mm A120F6119S 1 64k Snap Ring, bearing to shaft rear, M, 2.25mm A120F6120S 1 65 Reverse Idler Gear A120F6088S 1 66 Thrust Washer, reverse idler A120F6090S 1 67 Shaft, reverse idler A120F6089S 1 68 Bolt, reverse idler retention A120F6091S 1 69 Gasket, bolt to casing A120F6092S 1 Function Code: 47.07, Page: 6 10 11 12 13 2 3 8 9 7 4 14 6 15 5 5 16 6 3 2 1 47.11 Service Parts List Function Code 47.11 Final Drive & Bearings Dep Part Description Remarks 01 Differential Assembly Includes items 2 to 6 + casing 01a Differential Assembly, limited slip 02 Option Part Number Qty A120F6205S 1 A120F6262S 1 Thrust Washer, planet gear A120F6209S 2 03 Pinion Gear, planet A120F6206S 2 04 Pinion Shaft A120F6208S 1 05 Pinion Gear, sun A120F6207S 2 06 Thrust Washer, sun gear, 0.95mm A120F6213S 1 06a Thrust Washer, sun gear, 1.00mm A120F6210S 2 06b Thrust Washer, sun gear, 1.05mm A120F6214S 1 06c Thrust Washer, sun gear, 1.10mm A120F6211S 1 06d Thrust Washer, sun gear, 1.15mm A120F6215S 1 06e Thrust Washer, sun gear, 1.20mm A120F6212S 1 07 Final Drive Gear A120F6204S 1 08 Bolt, gear to casing A120F6217S 8 09 Pin, gear to casing A120F6216S 1 10 Oil Seal, output, RH A120F6024S 1 11 Spacer, bearing to housing A120F6218 1 12 Bearing, taper roller, RH A120F6011S 1 Optional Function Code: 47.11, Page: 1 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.11 Final Drive & Bearings Dep Part Description 13 Remarks Option Part Number Qty Speedometer Drive Gear A120F6240S 1 14 Bearing, taper roller, LH A120F6010S 1 15 Shim, bearing to housing, AA, 2.10mm A120F6219S 1 15a Shim, bearing to housing, BB, 2.15mm A120F6220S 1 15b Shim, bearing to housing, CC, 2.20mm A120F6221S 1 15c Shim, bearing to housing, DD, 2.25mm A120F6222S 1 15d Shim, bearing to housing, EE, 2.30mm A120F6223S 1 15e Shim, bearing to housing, FF, 2.35mm A120F6224S 1 15f Shim, bearing to housing, GG, 2.40mm A120F6225S 1 15g Shim, bearing to housing, HH, 2.45mm A120F6226S 1 15jh Shim, bearing to housing, JJ, 2.50mm A120F6227S 1 15i Shim, bearing to housing, KK, 2.55mm A120F6228S 1 15j Shim, bearing to housing, LL, 2.60mm A120F6229S 1 15k Shim, bearing to housing, MM, 2.65mm A120F6230S 1 15l Shim, bearing to housing, NN, 2.70mm A120F6231S 1 15m Shim, bearing to housing, PP, 2.75mm A120F6232S 1 15n Shim, bearing to housing, QQ, 2.80mm A120F6233S 1 15o Shim, bearing to housing, RR, 2.85mm A120F6234S 1 15p Shim, bearing to housing, SS, 2.90mm A120F6235S 1 15q Shim, bearing to housing, TT, 2.95mm A120F6236S 1 15r Shim, bearing to housing, UU, 3.00mm A120F6237S 1 Function Code: 47.11, Page: 2 2005/02 UPDATE ISSUED SEPTEMBER 2005 Function Code 47.11 Final Drive & Bearings Dep Part Description 16 Oil Seal, ouput, LH Remarks Option Part Number Qty A120F6035S 1 Function Code: 47.11, Page: 3 2005/02 UPDATE ISSUED SEPTEMBER 2005 3 11 7 5 13 12 8 2 10 6 1 9 7 4 47.15 Function Code 47.15 Driveshafts & Seals Dep Part Description 01 Remarks Option Part Number Qty Drive Shaft Assembly, LH A120D0019F 1 02 Drive Shaft Assembly, RH A120D0018F 1 03 CV Joint & Shaft Assy., outboard, RH A120D0017S 1 04 CV Joint & Shaft Assy., outboard, LH A120D0020S 1 05 CV Joint Assy., inboard, RH A120D0021S 1 06 CV Joint Assy., intboard, LH A120D0022S 1 07 Gaiter Kit, outboard CV joint A120D6002S 2 08 Gaiter Kit, inboard CV joint A120D6003S 2 09 Oil Seal, output, RH A120F6024S 1 10 Oil Seal, output, LH A120F6035S 1 11 Bracket, driveshaft bearing A120E6410S 1 12 Bolt, M10 x 32, flg. hd., bracket to engine A120E6412S 3 13 Bolt, flg. hd., shaft assy. to bracket A120E6411S 2 Function Code: 47.15, Page: 1 See 34.01 1 2 3 See 10.31 60.01 Service Parts List Function Code 60.01 Tool Kit Dep Part Description Remarks 01 Tool Kit Includes items: 2,3, towing eye & wheel bolt adaptor 02 03 Option Part Number Qty A117T0009S 1 Allen Key, M5 x 160 A117T6001H 1 Allen Key, M3 x 63 A117T6002H 1 Function Code: 60.01, Page: 1 7 6 3 4 8 5 2 1 60.01a Function Code 60.01a Diagnostic Equipment Dep Part Description 01 Remarks Part Number Qty Lotus Scan IIl Kit T000T1467F 1 02 Lotus Scan IIl, scanner tool T000T1426F 1 03 Printer T000T1419F 1 05 Lead, scanner to ALDL connector, blue T000T1457F 1 06 Lead, scanner to printer T000T1429F 1 07 Lead, scanner to PC T000T1430F 1 08 Adaptor, transformer to scanner T000T1436F 1 09 Plug Adaptor, Euro, transformer T000T1421F 1 Not illustrated, UK to European plug Option Function Code: 60.01a, Page: 1 Function Code 60.02 Special Tools Dep Part Description 01 Remarks Option Part Number Qty Hanger, engine T000T1437S 2 02 Press Tool, driveshaft T000T1438S 1 03 Press Tool, driveshaft bearing T000T1439S 1 04 Bolt, engine hanger T000T1440S 2 05 Oil Filter Wrench T000T1441S 1 06 Valve Clearance Adjuster Set T000T1442S 1 07 Crank Pulley Holding Tool T000T1443S 1 08 Companion Flange Holding Tool T000T1444S 1 09 Oil Seal Puller, transmission T000T1445S 1 10 Differential Pre-load Adaptor T000T1446S 1 11 Upper Plate, 5th/6th gear T000T1447/1 1 12 Bolt, 5th/6th gear puller T000T1447/2 1 13 Arm, 5th/6th gear puller T000T1447/3 3 14 Adaptor, 5th/6th gear puller T000T1447/4 1 15 5th/6th Synchro Puller Hanger T000T1448/1 1 16 5th/6th Synchro Puller Side Arm T000T1448/2 2 17 5th/6th Synchro Puller Bolt T000T1446/3 1 18 5th/6th Synchro Puller Claw T000T1446/4 2 19 5th/6th Synchro Puller Holder T000T1448/5 1 20 Fuel Pipe Release Tool T000T1450F 1 21 Fuel Gauge Kit T000T1451F 1 Function Code: 60.02, Page: 1 Function Code 60.02 Special Tools Dep Part Description 22 Remarks Option Part Number Qty Fuel Measure Set T000T1452F 1 23 Fuel Tube Connector T000T1453F 1 24 Fuel Tank Connector T000T1454F 1 25 Driveshaft Seal Tool, LH T000T1459F 1 26 Handle, driveshaft seal tool T000T1460F 1 27 Arm, transmision puller kit T000T1462F 1 28 Attachment, transmision puller kit T000T1463F 1 29 Claw, transmision puller kit T000T1464F 1 30 Adaptor, transmision puller kit T000T1465F 1 31 Tool Board T000T1455F 1 Function Code: 60.02, Page: 2 80.20a Function Code 80.20a Touch-in Paint Pencil Range Dep Part Description 71 Remarks Option Part Number Qty B71, Old English White A082B6404F 1 84 B84, Lava Orange Pearlescent A082B6385F 1 86 B86, Racing Green Metallic A082B6388F 1 93 B93. Starlight Black Metallic A082B6402F 1 94 B94, Ardent Red A082B6400F 1 97 B97, Atlantic Blue Metalllic A082B6407F 1 98 B98, Storm Titanium A082B6408F 1 100 B100, Magnetic Blue A082B6410F 1 101 B101, Electric Green Metallic A082B6411F 1 102 B102, Aubergine Metallic A082B6412F 1 104 B104, Blue Mica A082B6414F 1 105 B105, Nightfall Blue A082B6415F 1 106 B106, Saffron Yellow A082B6416F 1 107 B107, Glacier Blue A082B6417F 1 108 B108, Graphite Grey A082B6418F 1 109 B109, Krypton Green A082B6419F 1 Function Code: 80.20a, Page: 1