ECO LOTUS ELISE 2005 Repair Manual

Use only a non-mineral type DOT 4 brake fluid from a sealed
container marked with a yellow and black (non-mineral) symbol.
Do not use DOT 5 silicone fluid, or any fluid which has been
exposed to the atmosphere for more than a brief period, or
any fluid suspected of being wet, dirty or contaminated. Do not over fill, and replace the cap securely. Brake fluid, being hygroscopic, absorbs water from the atmos
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phere over a period of time, resulting in a lowering of the boiling
point of the fluid, and corrosion of the hydraulic system. For
optimum safety and brake performance, the brake fluid should be renewed every twelve months by your Lotus Dealer.
WARNING:
• Brake fluid is hazardous to health and may be fatal if swallowed. Keep out of children’s reach.
• Using the wrong type of brake fluid can damage brake system components and result in brake failure causing a
crash in which you and others could be killed or seriously
injured. See ‘Recommended Lubricants’.
Brake Pads The thickness of the brake pad lining material should be
checked at every service, and under no circumstances be al
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lowed to fall below 0.1 inch (2.5 mm). If the brakes are in very frequent or arduous use, as when driving in mountainous terrain,
or on race circuits, it is recommended that they be examined
more frequently. The pads should be renewed if of insufficient
thickness to ensure safe braking until the next scheduled service.
Note that in order to ensure that brake pads with the correct
material specification are used, only genuine Lotus replacement parts should be fitted, and in the interests of safety, pad renewal
should be entrusted to your Lotus dealer.
WARNING: Using incorrect brake pads, or pads below 0.1 inch
(2.5mm) thickness, may cause a crash in which you or
others could be killed or seriously injured. With a new car, or new brake system components, maxi
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mum braking efficiency will be achieved if, for the first few
hundred miles, needless heavy braking is avoided, and the
brake pads and discs are allowed to ‘bed in’ fully before
being used to their full potential (see also ‘Footbrake’).
Servicing & Maintenance
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Brake Pipes & HosesAt the recommended service intervals, the brake pipes and
flexible hoses should be carefully examined for signs of dam
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age, corrosion or perishing, especially in territories where salt is used on the road surface in the winter months.
Servicing & Maintenance
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Auxiliary Drive BeltA single, multi-rib type auxiliary belt is used to transmit drive
from the crankshaft to the alternator, water pump, and (if fitted)
air conditioning compressor. The belt is automatically tensioned,
and requires no periodic maintenance other than a visual check of its condition. If the belt exhibits any evidence of physical dam
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age, cracking, fraying, perishing, abrasion or contamination, it
should be renewed. In the case of contamination, the cause
must be identified and rectified, and each of the pulleys must be thoroughly degreased before the new belt is fitted. It is recommended that auxiliary belt replacement be en
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trusted to your Lotus dealer.
Sparking Plugs The Elise uses a direct ignition system with an individual
high tension coil mounted atop each of the four spark plugs and protected by a plastic cover, screw fixed to the engine.
WARNING: The voltages produced with this ignition system can
cause serious and potentially fatal injur y. Never touch
any ignition components when the engine is running or being cranked.
The spark plugs should be renewed in accordance with the
Maintenance Schedule, with the gaps set to 0.043 in. (1.1 mm).
This operation should be entrusted to your Lotus dealer.
Servicing & Maintenance
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TIRES AND WHEELS
TiresGlossary of Terms:Recommended inflation pressure: The cold tire inflation pressure which is recommended for this car and is speci
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fied in the ‘Technical Data’ section of this handbook.
Cold tire inflation pressure: All tires must be cold, meaning
that the car has been stationary for a minimum of 3 hours, or has been driven less than 1 mile. Adjust pressures only
in ambient conditions.
Maximum inflation pressure: The maximum inflation pres
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sure to which the tire should be subjected. For the Elise,
use only the recommended inflation pressure.
Lotus engineers have worked with tire manufacturers
to produce tire specifications for the Elise which optimise performance on both road and track. To ensure that any
replacement tires are to the correct Lotus specification,
always refer to your Lotus dealer, who will have the latest recommendations.
WARNING: In order to achieve the optimum handling char
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acteristics, the wheel and tire sizes on the Elise are different front and rear. This means that interchanging
of wheels and tires between axles is not permissible.
Failure to adhere to this requirement will adversely affect the handling of the car and may result in an
accident in which you or others could be killed or seriously injured,
The tires should be regularly inspected for signs of cuts,
abrasions or other damage, and for any uneven tread
wear patterns. Uneven treadwear may indicate that the suspension geometry or dampers require attention from
your dealer.
Tires & Wheels
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NOTICE:
• On cars used on a race track or in a competitive manner,
special vigilance is required due to the severity of tire operating conditions, with careful inspections carried
out between sessions.
• Take care when parking to avoid tire contact with high
or sharp edged kerbs. Such mistreatment can cause
internal damage to the tire structure and this may not be readily apparent. The wheel rims may also be distorted or damaged by careless parking, and result in wheel
imbalance or loss of tire pressure. Similar damage may also be caused by potholes, rocks or other highway
debris.
WARNING:
• Damage to wheels and tires may cause an accident in which you or others may be killed or seriously
injured. If the wheels or tires have been damaged,
have them replaced.
• Safety considerations should always be paramount when assessing tire condition and serviceability, and the tires replaced if any doubt exists, or if the
legal tread depth limits are approached.
• Poorly maintained and improperly used tires are dangerous.
• Overloading your tires can cause overheating as a result of too much friction. You could have a blow
out and a serious accident in which you could be killed or seriously injured. See ‘Tire Placard La
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bel’.
• Underinflated tires pose the same danger as over loaded tires. The resulting accident could cause serious injury, or death. Check all tires frequently
and maintain at the recommended pressure. Tire
pressures should be checked only when the tires
are cold.
• Overinflated tires are more likely to be cut, punc- tured or broken by a sudden impact - such as hitting a pothole. Keep tires at the recommended pressure.
• Installing improper tires on your car can affect handling and stability. This can cause a crash
in which you can be killed or seriously injured.

Tires & Wheels
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Always use the size and type of tires recommended
in this handbook.
• Using incorrect tires or tires which are excessively worn or improperly inflated can cause a crash in
which you can be killed or seriously injured.
• Please note your car is not fitted with a low tire pressure tell tale lamp so it is especially important
that you regularly check the tire pressures.
When driving on wet roads, surface water is squeezed
out from between the tire and road. However excessive
speed or water depth can overwhelm the water clearing capability of the tread and lead to a condition called 'aq
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uaplaning' or ‘hydroplaning’, where the tire rides on a film of water and provides little or no grip on the road surface,
leading to a loss of control. This condition is more likely
to occur with worn tires having little depth of tread, or with incorrect tire pressures. Drivers should keep a vigilant check on tire wear and condition, and moderate their
speed in adverse weather conditions.
Tire Care Wear indicators are moulded into the bottom of the
tread grooves at intervals around the tire, indicated by small pointers on the outer tread blocks. The tires should
be replaced before being worn to this minimum legal
tread depth. The cold tire pressures should be checked every week,
or every 1,000 miles (1,700 km), whichever is the sooner,
and corrections made as necessary. See ‘Technical Data’
at the back of the handbook for tire pressures. For track
use, tire condition and pressures should be checked be
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fore each run. Under-inflation will cause excessive wear, rapid deterioration of the tire sidewalls and heavy steering,
whereas over-inflation results in a hard ride and increased susceptibility to tire damage. Both conditions will cause a degradation in the handling qualities. It is important that the tire pressures are adjusted only
when the Tires are cold (when the car has been standing for a minimum of 3 hours, or driven less than 1 mile), as the pressures may increase by 0.3 - 0.5 bar (4 - 8 lb/in²)
when the Tires are warmed to normal running temperature.
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Use a good quality proprietary tire pressure gauge and always replace the tire valve dust cap to prevent the
ingress of dirt and moisture into the valve, which could cause leakage. Many fuel filling stations provide tire inflation facilities,
which specific usage instructions should be carefully fol
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lowed. For tire pressure information, refer to ‘Technical
Data’ or the Certification Label on the driver’s door jamb
(see page 121).
Replacement Tires When replacing tires, refer to the ‘Technical Data’ sec
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tion in this handbook, or consult your dealer to check the current Lotus specification and recommendations. Do not
use tires which differ from these specifications.
WARNING: Note that some tread patterns are directional, so
that the tire must be fitted onto the wheel with regard
to which side of the car the wheel is to be used. In
these cases, a direction of rotation arrow is included in the tire sidewall markings.
When balancing the wheel and tire assemblies, the
wheels should be located by the centre spigot hole - NOT by the wheel bolt holes. In order to maintain the correct
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Direction of rotation arrow
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handling feel and minimum steering wheel shake, it is very
important that the radial and lateral run out of the Tires are to the high standard required by Lotus Cars. If any difficulty is experienced with replacement Tires, refer to
the tire manufacturer.
Tire Characteristics The Yokohama AD07 or A048 Tires fitted to the Elise
are suitable for all normal weather conditions, but are optimised for dry road sports driving. The constructions
of both tire types have been specially tailored for the
Elise and are identified by the letters ‘LTS’ moulded on the tire sidewalls. Ensure that any replacement Tires are similarly marked. The tire characteristics include good
feedback (‘feel’) from the road surface to the steering
wheel, a high level of steering linearity and response, and little performance degradation with the high temperatures
which may be reached in sports use. However, tire performance will decrease at low ambi
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ent temperatures, resulting in reduced levels of grip and
an increased susceptibility to damage from impacts. In
these conditions, especially below 15°F (-10°C), it is recommended to fit a car set of the recommended winter
Tires (see below).
Winter Tires If the car is to be used in ver y cold territories, or
driven on snow covered roads, it is recommended to fit a

car set of winter Tires developed specifically for such
conditions. Lotus approves the use of Pirelli 210 (front)
and 240 (rear) Snowsport winter Tires in sizes specified
in ‘Technical Data’. These Tires should be fitted on regular
Elise wheels.
WARNING:
• Winter Tires are optimised for use on snow covered roads. When used on roads free of snow, winter
Tires will produce different handling characteristics and less grip compared with regular Tires.
• When winter Tires are fitted, a maximum speed of 118 mph (190 km/h) must be observed.
• Pirelli Snowsport Tires are NOT suitable for stud
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Tires & Wheels
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WheelsEnsure that only original equipment, or Lotus approved wheel
and tire combinations are fitted. After the car has been used
on track, or in competition conditions, the wheels should be removed and thoroughly inspected for damage.
WARNING: After striking a pothole or kerb, the wheels should be
removed and the wheel and tire thoroughly inspected for
damage. Renew the wheel and /or tire if necessary. Safety
considerations should always be paramount and new parts
fitted in any cases of doubt.
Wheel Bolts The wheel bolts used on the Elise are of a special design to
suit the small diameter fixing tunnels in the wheel centres. The bolts have a 10 spline socket head, for which a special extension
tool is supplied with the car. A 17mm a/f deep socket and 1/2
inch square drive wrench should be applied to the extension tool,
with a tightening torque of 77 lbf.ft (105 Nm) required. To protect against wheel theft, one of the four bolts securing
each wheel is key coded, and requires a corresponding coded
socket wrench and 1/2 inch square drive extension. Rotate the coded socket until full engagement with the bolt head is ensured and take care to maintain the extension tool perpendicular to
the wheel face before applying release torque.
NOTICE: It is not recommended to use hammer action air tools on the coded bolts - use only manual tools.
Both the standard extension and coded socket tools are
stowed in the car tool kit, and should remain with the car at all
times to ensure that servicing may be performed. The key code
included in the tool kit should be recorded and kept safely with
the car documents, in case a replacement socket tool needs
to be ordered.
Wheel Alignment and Tire Balance The wheels on your car were aligned and balanced carefully
during the manufacture of your car to give you the longest tire
life and best overall performance.
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If the battery is to be disconnected, the following precautions
should be taken: i) Ensure that all electrical loads (e.g. lights) are switched off. If
the car is fitted with security coded audio equipment, check
that the code is available for entering after battery reconnec
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tion.
ii) Wait for at least ten seconds after switching off the ig-
nition to allow the engine management system to adjust the

setting of some components ready for re-starting.
iii) Ensure the alarm is disarmed. If the battery is disconnected
when armed, the alarm will be triggered.
iv) Disconnect the
negative (earth; black; ‘-’) battery cable first,
and re-connect last.
WARNING:
If the battery positive terminal is inadvertently earthed
(e.g. when using a spanner) whilst the negative terminal
is still connected, the resultant short circuit with heavy sparking and current flow could cause serious burns.
To remove the battery, pull off the breather pipe (if applicable),
release the single screw securing the clamp bracket at the
base of the battery, and manoeuvre the battery from the base
retaining shoe.
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Batter y clamp
Electrical
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