Lotus Elise / Lotus Exige. Instruction - part 27

Page 16

 

 

Lotus Service Notes   

 

 

    Section DH

Alignment  - optimum                Zero

        - tolerance range            0.5 mm toe out, to 0.7mm toe-in overall

Rear

Mid-laden ride height (reference height for geometry check)

        - front                   120 mm below front end of chassis siderail              

        - rear                    120 mm below rear end of chassis siderail 

Camber    - optimum                - 2.5°

        - tolerance range            - 2.0° to  - 2.7°; max.side/side  0.2°

Alignment  - optimum                1.8 mm (0.24°) toe-in each side  

        - tolerance range            1.5 to 2.0 mm  (0.20 to 0.27°) toe-in each side

                              max.side/side  0.3 mm (0.04°)

Super Sport Suspension Retrofit

To retro-fit Super Sport suspension to a Toyota powertrain Elise/Exige, the following parts and procedure 

may be used: 

Parts Required                      Part Number     Qty

Front Damper                      A120C0018H    2

Rear Damper                       A120D0046H    2

Front Spring                       A120C0019H    2   31.5/47.5 N/mm

Rear Spring                       A120D0047H    2   46.6/65 N/mm

OR

Front Spring/Damper Unit              A120C0017F    2

Rear Spring/Damper Unit               A120D0045F    2

'C' Spanner, spring seat adjust            A120C6001F    1

Cradle, tie wrap, reservoir mounting        A082W6293F    2

Tie Wrap, reservoir mounting            A075W6038Z    4

Screw, M5 x 20, cradle fixing             A075W5084F    2

Rawlnut, M5, cradle fixing              A075W6074F    2

Anti-Roll Bar, stiffened, adjustable          A111C0134S    1  Black

Mounting Clamp, Nylon                A111C0052F    2  >

Spacer Sleeve, mounting clamp           A111C0060F    2  >

Bolt, M5 x 45, cap head, clamp fixing        A082W2106F    2  >

Washer, flat, M5, clamp fixing            A075W4011Z    2  > Use with bar A111C0134S

Nyloc Nut, M5, clamp fixing              A100W3113F    2  >

Pivot Bolt, M10 x 45, lower wishbone front    A075W2065F    2  >

Washer, flat, M10, clamp to chassis        A075W4024Z    2  >

Anti-Roll Bar, std. rate, adjustable          A120C0020F    1  Yellow

Clamping Block, a.r.b. bush              A120C0021F    2  )

Pivot Bush, a.r.b.                    A120C6002F    2  )

Bolt, skt cap, M8x65, clamp to chassis       A125W7218F    4  ) Use with bar A120C0020F

Washer, flat, 25mm, clamp bolt            B075W4021Z    6  )

Washer, flat, 16mm, clamp bolt            A111W4175F    2  )

Nut, Nyloc, M8, clamp bolt              A075W3010Z    4  )

Optional Additions

Chassis Rear Brace Kit (recommended for track use and/or A048 tyres)

                              LOTAC05377    1

Forged wheels & A048 tyres             Refer to Parts List

Edging Strip, front wheelarch            A117B0559F    2       

Page 17

 

 

Lotus Service Notes   

 

 

    Section DH

Procedure

1.  Anti-Roll Bar - stiffened rate adjustable

 

Remove the anti-roll bar after first drilling out the rivets securing the reinforcing brackets between  the 

bottom of the crash structure and the chassis.

 

The adjustable anti-roll bar is secured by two Nylon clamps, fixed to the chassis via the front lower wish-

bone inboard front pivot bolt, with a 'top hat' section steel spacer preventing the clamp from being crushed.  

These hard type mountings provide optimum steering response but will transmit more noise and require 

periodic lubrication with MoS

2 

 grease at 3,000 mile (5,000 km) intervals.  

 

Modify the crash structure support bracket as necessary before refitting. 

 

 

 

Anti-Roll Bar - standard rate adjustable 

 

Remove the anti-roll bar after first drilling out the rivets securing the reinforcing brackets between the bot-

tom of the crash structure and the chassis.

 

Each split pivot bush incorporates a raised shoulder around its centre in order to engage with a groove in 

the two part clamp, and provide lateral location.  A pip on this shoulder locates in a hole in the clamp cap 

to prevent rotation of the bush.  No lubrication is required.

 

Each bush housing is clamped to the front face of the chassis with two cap head bolts inserted from the 

front, using large washers under their heads and lower fixing nuts, and a smaller washer beneath the up-

per fixing nut to fit within the chassis extrusion.  Torque tighten the clamp bolts to 25 Nm.

 

Refit crash structure brackets.

Anti-Roll Bar Mounting - Stiff adjustable 

   

                                    'Top hat' spacer

                                          Clamping block

                          M5 bolt

      Lower wishbone pivot bolt

                                          Anti-roll bar

 c40a

Anti-Roll Bar - Standard rate adjustable

                                      Bearing clamp rear

                                          Alignment dowel                 

 

                                            Anti-rotation pip   

  Smaller washer                                       

                                                        Cap head bolt

                                                     

    Chassis

    front face

    Anti-roll bar        Plastic split bush     Bearing clamp cap    Flat washer          

c40b

                                 

Page 18

 

 

Lotus Service Notes   

 

 

    Section DH

2.  Modify Front Damper Bracket

 

Remove all four spring/damper units and front wheelarch liners (refer Service Notes section CI).

 

The upper eye of the alloy bodied Bilstein sport damper is larger than the standard steel eye and requires 

that the front suspension upper clevis bracket (bolted to the chassis), is modified in order to provide the 

necessary clearance.

 

File the bracket edge parallel with the damper eye axis as shown, and protect with a zinc rich anti-corro-

sion paint.

3.  Fit Spring/Damper Units

 

Unless fitting pre-assembled spring/damper units, use spring compressor clamps to assemble the new 

springs and dampers, taking all appropriate safety precautions.

 

Mount the rear units with the red dot on the damper lower body facing outboard.  Mount the front units in 

similar manner and secure each front remote reservoir to the front face of the body side using a saddle 

clip and two tie wraps as shown below.  Fix the saddle clip using an M5 Rawlnut (drill panel to 9.5mm) 

and screw.  Ensure that the reservoir and hose are positioned to clear the wiring harness and oil cooler 

pipe. 

       

                                    Tie wraps            Saddle clip

      Damper reservoir

     

      Ensure clearance

      Oil cooler hose

      Wiring harness

     

      Front face of body side

                                                                   

c46

                                                New profile shown solid;  

                                                Original condition dotted

                                                                     

c45

Page 19

 

 

Lotus Service Notes   

 

 

    Section DH

4.  Damper Adjustment

 

For damper adjustment, see above.

5.  Chassis Rear Brace Kit

 

The chassis brace kit is fully described in Section DH.5.

6.  Forged Wheels

 

The lightweight forged wheels offer a saving of 14.4 kg/car on Elise and 20.4 kg/car for Exige, and feature 

a wider front rim width of 6.5J.  Insets are unchanged.

7.  Yokohama A048 Tyres

 

The Yokohama A048 tyres, have been developed jointly by Lotus and Yokohama to suit the requirements 

of the performance driver, with special emphasis on track use.  Compared with the standard tyre, the 

front tyre width is increased and the profile reduced from 175/55 to 195/50.  The tyre tread design is di-

rectional, such that each wheel/tyre assembly is dedicated to a single vehicle corner.  Tyre pressures are 

unchanged.

 

The Lotus specific construction is identified by the letters 'LTS' moulded on the tyre sidewall.  Ensure that 

any replacement tyre is so marked. 

8.  Front Wheelarch Edging Strip

 

In order to comply with tyre coverage regulations, fitment of A048 tyres requires that edging strip A117B0559F 

is applied around both front wheelarches, and secured with Permabond C2 or similar adhesive.

9.  Geometry

 

For front and rear suspension geometry settings, see earlier in this section.