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Lotus Elise / Lotus Exige. Instruction - part 30

Page 9

Lotus Service Notes

Section EH

removal. Start the engine and check for oil leaks. Re-check the security of the ﬁlter, further tightening by hand

if necessary. Check the oil level (see above) when the engine is fully warm.

Oil Coolers

The foregoing oil change procedure does not disturb the oil quantity contained in the twin oil coolers and

associated pipework, but is considered perfectly satisfactory for routine maintenance operations. In instances

of major engine failure where the oil system may be contaminated with metallic debris, all oil cooler lines should

be thoroughly ﬂushed out and the oil cooler radiators replaced.

If the oil cooler circuit is drained or replaced, the following procedure should be adopted to ﬁll the cooler

system before starting the engine:

1. Attach a tube to the bleed nipple on the sandwich plate between oil ﬁlter and engine block, and lead into

a catch tank. Open the bleed nipple.

2. Disconnect the outlet hose from the top of the LH oil cooler, and pour engine oil into the cooler until oil

reaches the bleed nipple (approx. 2.5 litres). Close the bleed nipple, tightening to 8 Nm.

3. Connect the LH cooler outlet hose and tighten to 40 Nm.

4. Add a further 0.7 litres of oil into the engine to accommodate the volume of the return hose between LH

oil cooler and engine.

5. After starting the engine, restrict running to idle speed for a minimum of 5 minutes, to allow the oil cooler

lines to be purged of air. Stop engine and re-check oil level.

Note: For cars ﬁtted with an Accusump pressurised oil storage canister, refer to separate literature.

Oil cooler feed hose

Oil cooler return hose

Sandwich plate

bleed nipple

Oil ﬁlter canister

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Lotus Service Notes

Section EH

Page 10

Air Cleaner Element

The air ﬁlter should be inspected at intervals dependent on the operating conditions. When the vehicle is

operated in a relatively clean environment, the element should be renewed at intervals speciﬁed in the Main-

tenance Schedule, but where a dusty or smog laden atmosphere prevails, or other factors contribute to ﬁlter

contamination, more frequent replacement will be required dependent on the level of pollution.

A disposable folded paper type air

cleaner element is ﬁtted in a housing at the

left hand front of the engine bay. For access

to the element, the left hand rear wheel and

wheelarch liner must ﬁrst be removed. Before

opening the air cleaner housing, the wheelarch

area should be cleaned to reduce the possibil-

ity of ﬁlter or housing contamination with road

dirt.

To open the ﬁlter housing, release the

two spring clips at the outboard end of the

housing, and hinge open sufﬁciently to allow

the element to be withdrawn.

Clean the inside of the housing, including the joint faces, taking care not to contaminate the ‘clean’ engine

side of the assembly. Fit the new ﬁlter element into position with the shallow side facing the 'clean', engine

side of the housing. Ensure that the hinge lugs at the inboard end of the housing are correctly engaged before

closing the housing and securing with the two spring clips. Reﬁt the wheelarch liner and rear wheel.

Auxiliary Drive Belt

A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump,

alternator and a.c. compressor, with a slave pulley ﬁtted in place of the power steering pump used in other

applications. A hydraulically damped, spring loaded tensioner arm applies tension to the back of the belt, and

is maintenance free. The belt itself should be inspected for condition at each service interval, and if it exhibits

any evidence of physical damage, cracking, fraying, perishing, abrasion or contamination, it should be replaced.

In the case of oil or coolant contamination, the cause must be identiﬁed and rectiﬁed, and each of the pulleys

must be thoroughly degreased before the new belt is ﬁtted.

For further details, refer to section CH in the Engine Repair Instruction, but note that only a six-sided socket

should be used on the cast boss on the tensioner arm. Due to the manufacturing draft angle of the casting, a

twelve point socket is liable to cause damage.

Spark Plugs

The ignition system uses a distributorless ignition system (DIS) which employs an individual high tension

coil for each of the four spark plugs. Each coil is mounted directly onto its spark plug using an integral connector

and is secured to the cam cover with a single screw. The spark plugs use small diameter centre electrodes made

of iridium for long life and high performance, and require changing only at 54,000 mile (90,000 km) intervals.

For further details, refer to section IG in the Engine Repair Instruction.

AIR CLEANER

ELEMENT

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Lotus Service Notes

Section EH

EH.3 - ENGINE REMOVAL/REPLACEMENT

It is recommended to remove the rear clamshell prior to powertrain removal in order to improve access,

and to reduce the possibility of paint damage. The engine may be removed from above, with or without the

transmission. The following procedure applies to the engine/transmission assembly, but to avoid disturbing

the suspension, refer to sub-section FJ.5 to separate the engine from the transmission before withdrawing the

engine alone.

Fuel Pressure Relief Procedure

This procedure should be used prior to disconnecting any part of the fuel line.

Pull out the fuel pump fuse (on the left

hand side of the engine bay bulkhead, as

shown), start the engine, and run until it

stops from starvation. Crank the engine

for a further few seconds.

If the engine is a non-runner, pull out the

fuel pump fuse, and crank the engine

for 20 seconds to minimise residual fuel

pressure.

Disconnect the battery.

It is recommended ﬁrst to release the

quick ﬁt connector located to the rear of

the coolant header tank:

Release the retaining clip securing the

pipe joint to the header tank bracket.

Slide the orange coloured safety lock to

allow access to the connector release

buttons.

Surround the pipe joint with a shop towel

to absorb fuel contained in the pipework

before pressing the release buttons and

separating the joint.

WARNING: Be aware of the possibility of full pressure retention in the fuel line caused by a system

fault.

Before re-making the joint, ensure that the or-

ange safety lock is ﬁtted onto the pipe connector

in the orientation shown in the illustration.

Push the male pipe end fully into the female

connector until a click is heard. Pull on the pipe

to ensure complete engagement.

Slide the orange safety lock over the connector

to prevent accidental pressing of the release

buttons.

Secure the pipe/connector using the pipe clip

on the header tank bracket.

Fuel pump

fuse (20A)

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Fuel pipe to

Orange

engine

safety lock

Fuel pipe

from tank

Release

button

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Lotus Service Notes

Section EH

Page 12

1. Remove the engine bay undertray and diffuser, both rear road wheels and the rear clamshell (see sub-

section BR.7).

2. On a.c. cars, recover refrigerant and disconnect both a.c. hoses from the pipes at the rear of the RH

sill.

From beneath the car:

3. Drain coolant, transmission oil and, if necessary, engine oil. Diconnect the coolant inlet hose from the

thermosat housing and cap both apertures. Disconnect the two oil cooler hoses from the sandwich plate

and cap all ports and hoses.

4. Disconnect the exhaust manifold from the downpipe.

5. Release the gear cable routing clips from beneath the engine. Disconnect the earth braid between chas-

sis and transmission.

6. Release the clutch slave cylinder from the transmission housing and support aside.

7. Release the steady mounting between the front of the engine and the chassis, and between the rear of

the engine and the subframe.

From above:

8. Release the gearchange cables from the transmission by removing the 'R' clips retaining the inner cable

eyes, and the 'C' clips retaining the outer cables.

9. Disconnect the air intake hose between air cleaner and intake plenum, and release the brake servo vacuum

hose from the intake plenum.

10. Disconnect the throttle cable. Disconnect the radiator feed hose and heater feed hose from the rear end of

the cylinder head. Disconnect the heater return hose from the water rail, and the two hoses and electrical

connector from the header tank. Disconnect the re-circ. pump hose to the chassis pipe, and release the

electrical connector. Unplug the engine harness. Release the header tank bracket from the subframe,

and remove the bracket complete with tank and recirc. pump. Release the purge pipe from the throttle

body.

11. Remove the LH driveshaft from the transmission:

Release the top ball joint plinth from the LH hub carrier noting and retaining the camber adjustment shims,

and separate the toe-link ball joint separated from the carrier. The driveshaft inboard joint is retained in

the transmission by a round section circlip. The joint may be removed by applying a shock pull to the C.V.

joint body using a slide hammer with a forked end. Take great care not to damage the output oil seal on

withdrawal.

CAUTION: Do NOT attempt to remove the inboard C.V. joint from the transmission by pulling on the

driveshaft. The balls of the inboard joint are restrained for transit purposes only, by a circlip at the end

of the ball tracks. Applying an extension force to the joint will damage the balls and require joint replace-

ment. Apply pressure only to the outer body of the joint. Do not allow the brake hose to be stetched or

stressed, and support the driveshaft after withdrawal to protect the shaft joints and hub carrier. Cap the

driveshaft aperture in the transmission.

12. Remove the RH driveshaft from the transmission:

Release the top ball joint plinth from the RH hub carrier noting and retaining the camber adjustment shims,

and separate the toe-link ball joint separated from the carrier. The right hand driveshaft incorporates

a bearing for the extension shaft and it is this which retains the shaft in the transmission. Remove the

two bolts ecuring the bearing bracket, and withdraw the complete shaft assembly taking great care not

to damage the ouput oil seal. Do not allow the brake hose to be stetched or stressed, and support the

driveshaft after withdrawal to protect the shaft joints and hub carrier. Cap the driveshaft aperture in the

transmission.

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