ECO LOTUS ELISE 2005 Workshop Manual

SERVICING AND MAINTENANCEBODYCARE
Body Features Lotus are among the world leaders in the field of automotive
composite moulding design and manufacturing techniques.
Composite materials have major advantages for specialist car bodies, and these brief notes introduce some features of the
construction and service properties of automotive composite bodies. The manufacturing process enables the thickness of com
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posite mouldings to be varied in order to provide ef ficient structures of high strength and low weight. Composites will not
corrode, so the strength of composite components is retained regardless of age, unless physical damage is sustained. On
the Elise, the body construction utilises several mouldings to
form a single unit for the whole of the nose and front wings, and
a second unit for the whole of the rear body aft of the doors.
These two moulded assemblies are fixed using threaded fasten
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ers to permit easy removal for access to chassis or powertrain
components, or to allow simple and economic accident repair.
Other composite mouldings include the door shells, sills, front access panels, windscreen frame and rear bulkhead, some panels being bonded to the aluminium alloy chassis with an
elastomeric adhesive.
Several different processes are used to manufacture the
various panels depending on the functional requirements, with the main outer panels using an injection compression mould
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ing technique which eliminates the ‘gelcoat’ used on the outer
surface of conventionally manufactured composite panels. This
process provides considerably increased resistance to surface
damage from minor knocks, where a conventional composite panel would suffer cracking of the gel coat, or a steel panel be
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come dented. If severe damage is caused to a composite panel
where the underlying structure is broken, repairs may take the
form of panel replacement, or of panel repair using techniques
where new composite material is integrated with the old to result in undiminished panel strength.
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NOTICE: The Elise is not equipped with conventional separate shock absorbing bumpers, so extra care should be taken when parking to guard against body damage. The Lotus Elise does
not offer the same kind and degree of impact resistance or
energy absorption afforded by conventional U.S. bumper sys
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tems. Care is also required, due to the low ground clearance, to guard against car underside damage caused by ramps, kerbs
and road humps.
Paint Care The acr ylic enamel finish of the Lotus Elise is extremely
resistant to all normal forms of atmospheric attack. Following
the simple maintenance procedure summarised below will help retain the gloss, colour and protective properties of the paint
throughout the life of the car. However, car finishes are not im
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mune to damage and amongst the more common causes of deterioration are:
- Atmospheric contaminants; dust, soot, ash, and acidic or
alkaline aerosol mist can chemically attack paint.
- Abrasion; blowing sand and dust, or a dirty washing cloth.
- Tree sap and insect fluids; can form a water-insoluble polymer
that adheres to the paint.
- Bird excrement; highly acidic or alkaline, they can chemically etch the paint. Wash off immediately.
- Leaves; contain tannic acid which can stain light finishes.
- Impact damage; granite chippings thrown up from poor or recently dressed road surfaces can subject the body to severe
localised impact, and result in paint chips, especially around
the vulnerable frontal panels. Do not follow other cars too closely in such circumstances. For optimum paintwork pro
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tection, Lotus recommends the use of a self adhesive film kit
which your dealer will be pleased to supply and/or fit.
- Moisture entrapment; Long term use of a non-breathable car cover can trap moisture and/or induce condensation and promote water penetration of the paint film.
Ventilation Water lying on the paint surface for a lengthy period will even
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tually penetrate the paint film. Although the effects will not be
visible immediately, a deterioration in the protective properties
of the paint film will ultimately result.
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It is not recommended to store a wet car in a poorly ventilated
garage. If good ventilation cannot be provided, storage outside
on a hard standing or under a carport is to be preferred.
Paintwork Polishing Eventually some loss of gloss, and an accumulation of traffic
film, will occur. At this stage, after normal washing, the appli
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cation of a good quality liquid polish will restore the original lustre of the paint film.
Higher gloss of the paint finish, and added protection against
contamination, can be obtained by the use of a wax polish.
However, this can only be used successfully on a clean surface,
from which the previous application has been removed with white
spirit or a liquid polish cleaner.
Washing NOTICE: Lotus recommends hand washing of the painted
bodywork. The car is a speciality sports vehicle not intended
to go through an automatic car wash. Automatic car washing machines and jet wash facilities may have a detrimental effect on the paint film and the soft top. Use of automatic car washes
will invalidate the terms of the Limited Warranty.
Many contaminants are water soluble and can be removed
before any harm occurs by thorough washing with plenty of
lukewarm water, together with a proprietary car wash additive
(Household detergent and washing up liquid can contain cor
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rosive salts, and will remove wax and accelerate oxidation).
Frequent washing is the best safeguard against both seen and
invisible contaminants. Wash in the shade, and use a cotton chenille wash mitt or a
sponge rinsed frequently to minimise the retension of dirt parti
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cles in the mitt or sponge. Use a straight back and forth washing motion to avoid swirled micro scratches, and rinse thoroughly.
In order to minimise degradation from road salt, the underside
of the chassis should be rinsed with clean water as soon as possible after driving on treated roads. Many fuel filling stations
offer pressure washing facilities ideal for this purpose, but do
not use on the painted bodywork or soft top roof.
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Soft Top Roof
1. Careful vacuuming of the soft top before washing may be
helpful in removing excess dust and other foreign particles.
2. Wash in partial shade rather than strong sunlight.
3. Using only clean lukewarm water and a sponge (a chamois or
cloth will leave lint, and a brush may abrade the threads), wash
the entire soft top uniformly. Do NOT use a detergent, which may
affect the waterproofing properties of the material.
4. Rinse the whole car to prevent streaking on the paintwork. 5. Remove surface water with a sponge and allow to air dry in direct sunlight. Ensure that the roof is fully dry before stow
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ing, as prolonged stowage of a wet or damp roof will promote
rotting of the fabric.
Keeping the soft top clean by regular washing will enhance
the life and maintain the appearance of the roof, and facilitate subsequent cleaning. The use of stronger cleansers should be left to professionals experienced in handling this type of fabric
as discoloration and degradation of the material may result.
The application of wax finishes, dressings or preservatives may cause stains, and should be avoided. Your dealer will be able to advise on current Lotus approved soft top care products.
Windscreen Cleaning When washing the windscreen, take care to lift the wiper
blade only a small distance from the glass in order not to dam
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age the wiper arm mechanism. Wash the wiper blade with

clean water.
Alloy Road Wheels It is recommended that the aluminium alloy road wheels
are washed with the same preparation as is used to wash the bodywork. Use a brush having only nylon bristles. During the
winter months, particularly when salt has been used on the
roads for the dispersal of snow and ice, remove all the wheels,
and wash thoroughly to remove all accumulated road filth from
the wheels and Tires. Be aware that on cars fitted with optional clear anodised
forged alloy wheels (with 7 twin-spokes), the anodised surface
finish may be attacked by some proprietary wheel cleaning products. Wash only using hot soapy water or car bodywork
shampoo. Advise tire fitting companies accordingly.
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Upholstery Cleaning
Cloth Trim:
Normal cleaning consists of an occasional light wipe
over with a cloth dampened in a mild soap and water solution; it
is important that the cloth is only dampened, not soaked. Alter
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natively, a proprietary upholstery cleaner may be used.
Leather Trim:
The leather should be wiped over occasionally with
a cloth dampened in warm soapy water. Use a mild, non-caustic
toilet soap or soap flakes. Repeat the operation using a fresh
cloth and water only, but avoid flooding the leather. Finish by drying and polishing with a soft dry cloth. The manufacturers
of the leather do not recommend the use of any hide 'food',
and prohibit the use of petrol or detergents, furniture creams

and polishes.
NOTICE: Lotus cars are upholstered with premium quality
leather specifically tanned and dyed for automotive use. As a
natural material, leather ages in various ways and may, over time,
exhibit signs of cracking, scuffing, shrinking, etc. Such wear is not an indication of a defect, but rather the natural maturing of
the leather.
Seat Belts Cleaning The seat belts may be sponged with warm water and should
be allowed to air dry naturally before use. Do not use chemical
cleaners and never attempt to bleach or dye the webbing.
Footwell Cleaning Each time the car is washed, the footwell carpet mats should
be lifted and the floor surface cleaned and dried.
NOTICE: Use only correctly retained Lotus approved carpet mats in the footwells. Floor coverings made from plastic or other
non-breathable materials may trap moisture and initiate surface
corrosion of the footwell floors. Any damage caused by the use of incorrect mats will not be covered by your Limited Warranty.
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OWNER MAINTENANCERemember that fuel consumption and wear and tear of the
car are affected considerably by the way the car is driven and maintained. Be sure to carry out the simple maintenance checks detailed below, and to have your car serviced regularly by your
Lotus dealer, in order to ensure maximum safety, reliability,
longevity and pleasure of ownership.
NOTICE: Failure to follow and comply with the Maintenance
Schedule may invalidate the terms of the warranty.
The Lotus Elise has been designed as a road going sports
car. It is recognised that owners may wish to use the car occa
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sionally on closed circuit tracks to experience the car’s full range of dynamic capabilities. However, use of the car in a competitive
manner, including timed runs or laps, is not endorsed by Lotus.
Using the car on the track may cause a greater degree of wear and tear on parts and such wear and tear on parts and compo
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nents will not be covered by your Limited Warranty.
WARNING: Any type of timed, competitive car use will invalidate
warranty and require appropriate levels of expert car prepa
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ration and servicing.
WARNING:
• Attempts at car servicing with inadequate knowledge, tools or equipment, could result in car damage as well as
endangering you, your passenger and other road users.
Consult your Lotus dealer in all cases of doubt.
• Beware of hot surfaces in the engine bay. You could be seriously burned if you touch a hot engine part.
• Take great care not to drop flammable liquids or objects onto a hot engine and start a fire.
• Ensure that only Lotus dealers or suitably qualified tech
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nicians work on the airbag system.
• Beware of rotating engine components; to avoid injury,
guard against entrapment of tools, body parts and loose
clothing.
• The front mounted electric fans can start up and cause injury even when the engine is not running. Keep tools,
hands and clothing well away.
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pressing firmly to ensure that the handle is fully seated. With-
draw the dipstick again to inspect the oil level, which should lie between the two dimples on the end of the stick. The oil level
should be maintained at the upper of these two marks in order
to provide optimum engine protection.
Topping Up
: If topping up is necessary, unscrew the oil filler cap
from the left hand end of the cam cover. Add a suitable quantity of the recommended engine oil (see ‘Recommended Lubricants’)
taking care not to spill any oil onto engine or electrical compo
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nents; use a funnel if necessary. The difference between high and low dipstick marks is equiv
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alent to 1.6 U.S. quarts (1.5 litre). Allow several minutes for the oil to drain through to the sump before re-checking the oil level.
Do NOT over fill, or lubrication will be degraded and consump
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tion increased as the oil becomes aerated. Refit the filler cap,
turning clockwise until secure.
Engine Oil Change The use of high quality oil, renewed at the specified intervals,
is the key to engine longevity and sustained performance. Ad
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here strictly to the engine oil and filter change intervals specified
in the Maintenance Schedule.
For access to the engine sump and filter, the engine bay
undertray must first be removed. This is most easily achieved
with the car raised on a garage hydraulic lift, or alternatively, parked over an inspection pit.
The drain plug is located at the rear of the sump, and should
be removed to drain the sump immediately after a run when
the oil is warm and the impurities are still held in suspension.
On cars fitted with front mounted oil coolers, it is not necessary routinely to attempt to drain the cooler circuit. Servicing & Maintenance
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WARNING:
• Engine oil is hazardous to your health and may be fatal
if swallowed.
• Take all suitable precautions to guard against scalding
from the hot oil.
• Prolonged and repeated contact with used engine oil may cause serious skin disorders, including dermatitis

and cancer.
• Use protective gloves to avoid contact with skin as far
as possible and wash thoroughly after any contact.
• Keep out of reach of children.
Allow the oil to drain completely before cleaning the drain
plug, fitting a new sealing washer, and tightening securely. Refit
the undertray. Refill with the recommended lubricant (see page 153) via the
oil filler on the camshaft cover, to the top mark on the dipstick,
allowing several minutes for the oil to drain through to the sump before checking the level. Take care not to over fill. Refit the oil
filler cap securely, and check the oil level again when the engine is fully warm (see above).
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- Remove the plug, and check that the oil is level with the bottom of the hole. Note that the release of oil trapped
by the plug, should not be confused with an indication of

correct oil level.
- If necessary, add only the specified lubricant (see ‘Recom
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mended Lubricants’) via the level plug hole until the oil level
stabilises at the bottom of the plug hole.
- Refit the level plug with a new sealing washer, and tighten securely. Refit the undertray.
To renew transmission oil:
WARNING:
• Engine oil is hazardous to your health and may be fatal
if swallowed.
• Take all suitable precautions to guard against scalding
from the hot oil.
• Prolonged and repeated contact with used engine oil may cause serious skin disorders, including dermatitis and
cancer.
• Use protective gloves to avoid contact with skin as far as possible and wash thoroughly after any contact.
• Keep out of reach of children.
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f131
Transmission
filler/level plug
Drain plug

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exchangers from both frost damage, and metal corrosion. The
Elise is factory filled with a 50% concentration of Havoline XLC
Extended Life Coolant, which contains Organic Acid Technology
(OAT) based corrosion inhibitors to provide long coolant change intervals combined with freedom from environmentally damaging phosphates, silicates and nitrites.
NOTICE: No other type of coolant should be mixed with this
OAT coolant.
Havoline XLC may be identified by its orange colouration, and
by a label around the header tank filler neck. The 50% concen
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tration provides freezing protection down to - 40°F (- 40°C), and is recommended to be maintained throughout the life of the car.
Stronger concentrations should not be used. In an emergency, if an OAT coolant is not available, the
cooling system should be topped up using water only, but the reduction in freezing protection should be recognised, and the
concentration corrected promptly. In areas where the tap water is extremely hard (exceeding 250 parts per million), distilled, de-ionised or filtered rain water should be used for the water
content of the coolant mix. The effective level of ethylene glycol (anti-freeze) in the sys
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tem may be measured by your dealer using a hydrometer, but in order to ensure that the required level of corrosion protection is
maintained, the coolant should be renewed every 4 years. For coolant capacity, refer to ‘Recommended Lubricants‘
and ‘Technical Data’.
NOTICE: Using an incorrect coolant mixture may result in ex
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pensive damage to your engine and/or other car parts caused by overheating, freezing or corrosion effects. This damage would
not be covered by your new car warranty.
Coolant Drain /Refill Procedure The cooling system of the Lotus Elise has been carefully
optimised to allow the required cooling performance using the
minimum volume of coolant. This provides for high cooling sys
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tem efficiency, with quick engine warm up and interior heating. When refilling the cooling system, it is vital to ensure that
the correct bleeding procedure is followed, and that no air pockets remain. This operation should be entrusted to your
Lotus dealer.
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