engine LOTUS ELISE 2005 Repair Manual
[x] Cancel search | Manufacturer: LOTUS, Model Year: 2005, Model line: ELISE, Model: LOTUS ELISE 2005Pages: 205, PDF Size: 4.51 MB
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Unladen weight - total 912 kg ) inc.
(heaviest) - front 344 kg ) full fuel
- rear 568 kg ) tank
Max. weight - total 1162 kg > incl.
- front 441 kg > occupants
- rear 721 kg > & luggage
Trailer towing Not permissible
Capacities Engine oil (refill inc. filter) 4.7 U.S. qt. (4.4 litre)
(+3.7 U.S. qt (3.5) litre if front mounted oil coolers are drained) High/low dipstick mark difference 1.6 U.S. qt. (1.5 litre)
Transmission oil 2.4 U.S. qt. (2.3 litre)
Fuel tank 10.6 U.S. gall. (40 litre)
Cooling system 12.7 U.S. qt. (12 litre)
A.C. refrigerant (R134a) 1.2 lb (0.55 kg)
Front Suspension
T ype Independent. Upper and
lower wishbone co-axial
coil spring/telescopic
damper unit; anti-roll bar
Steering axis inclination 12° nominal
Geometry specification - Standard: Mid-laden ride height (reference height for geometry check)
- front 135 mm below front end
of chassis siderail
- rear 135 mm below rear end
of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°;
max. side/side 0.35°
Camber - optimum - 0.1°
- tolerance range + 0.1° to - 0.3°
max. side/side 0.2°
Alignment - optimum Zero - tolerance range 0.5 mm toe-out, to
0.7mm toe-in overall
Technical Data
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Camber - optimum - 1.8°
- tolerance range - 1.6° to - 2.0°
max.side/side 0.2°
Alignment - optimum 1.5 mm toe-in each side - tolerance range 1.2 to 1.8 mm toe-in each
side
max.side/side 0.3 mm
Electrical
Light Bulbs Watt. Type
Headlamps 55 H1 & H7
Front side/parking lamps 5 W5W
Front turn indicators 21 PY21w amber
Rear turn indicators 21 H21
Side repeater lamps 5 W Y5W amber
Stop lamps 21 H21
Tail/stop lamps 4/21 P21/4w
Tail/turn lamps 4/21 P21/4w
High mounted stop lamp 2.5 16 x LED
Reversing lamp 21 H21
Licence plate lamps 5 C5W
Interior lamp 5 W5W
System voltage/polarity 12V negative earth
Alternator 85A
Battery (service replacement)
- type Delco 19001598
- BCI code 26R- 6YR
- cranking power 550 amps @ -18°C
- reserve capacity 80 minutes
Engine
Type designation 2ZZ-GE
Cylinder configuration in-line 4
Capacity 1796 cm
3
Bore 82.0 mm
Stroke 85.0 mm
Camshafts Chain driven DOHC 4VPC
Valve actuation - inlet Variable timing and lift
- exhaust Variable lift
Compression ratio 11.5:1
Firing order 1,3,4,2
Technical Data
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Spark plugs NGK IFR6A11
DensoSK20R11
Spark plug gap 1.1 mm
Max. continuous engine speed 8000 rpm (8500 transient)
Fuel requirement Unleaded
Minimum octane 91 (RON+MON)/2
Fuel system Multi-point fully sequential
fuel injection with Lotus T4
controller.
Peak power (SAE DIN 70020) 190 bhp (141.7 kW) @
7,800 rpm
Peak torque (SAE DIN 70020) 138 lbf.ft (187 Nm) @
6,800 rpm
Transmission
Type 6 speed manual transaxle.
Bevel gear differential.
Gear Ratio Final Drive mph/1000 rpm First 3.17:1 ) 5.1
Second 2.05:1 ) 7.7
Third 1.48:1 ) 4.53:1 10.7
Fourth 1.17:1 ) 13.6
Fifth 0.92:1 ) 17.3
Sixth 0.81:1 ) 19.4
Reverse 3.25:1 )
Brakes
Type Front and rear discs with
curved vane ventilation
and cross drilling.
AP Racing aluminium op
posed piston front calipers.
Single piston sliding rear
calipers.
Disc Size - front and rear 288mm
Operation Tandem master cylinder
with vacuum servo and
ABS
Parking Brake Cable operation of rear
calipers, self adjusting for
pad wear.
Technical Data
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extent of such noises, including brake squeal, engine and
exhaust noise, gear whine, knocks, rattles and wind noise
will differ from car to car, with the level of acceptability being
determined by the Company.
n) 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 the natural maturing of the leather and is not covered under
warranty.
o) Salvage title or total loss; the warranty does not cover any
car which can no longer by used on the road because it only
has salvage value or has been declared as an insurance write
off due to an accident or damage.
6. OBLIGATIONS OF OWNERS. ALL WARRANTIES ARE
VOID IF OWNERS FAIL TO PROPERLY USE AND MAIN
-
TAIN THE CAR.
The Company has no obligation under this warranty in
the following circumstances:
• If the car has not been driven in accordance with the ‘Break-in’
instructions detailed in the Owner‘s Handbook;
• if the maintenance services and maintenance instructions specified in this Handbook are not performed and followed
at the prescribed intervals. Car owners must keep up to date
and accurate records of car service and maintenance in order
for any warranty claim to be considered;
• if the motor car is used for commercial service, or for racing or reliability trials, or in a competitive manner, including timed
runs or laps;
• if the motor car is registered or used outside the Continental United States, Canada, Hawaii, Puerto Rico, Alaska, Guam
and the United States Virgin Islands;
• if failure or malfunction of the motor car or of any warranted part, component or assembly results from an accident; or,
• if failure or malfunction is caused by misuse, abuse or neg
-
ligence in use of the motor car, including, but not limited to,
where the car is not driven on road surfaces which have been
maintained to a standard to allow regular vehicle traffic, or
Limited Warranty
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- fuel vapour pressure sensor
Exhaust System
- exhaust manifold
- catalytic converter, heat shields, gaskets and fasteners*
Engine Emission Control System Sensors
- electronic control module (ECM)*
- engine coolant temperature sensor (ECTS)
- air flow meter
- crankshaft sensor
- idle air control valve (IACV)
- wheel speed sensors
- throttle position sensor (TPS)
- knock sensor
- oxygen sensors
- oil control valves for VVTL-i
- oil pressure switch for VVTL-i
- camshaft position sensor
- coolant thermostat
On Board Diagnostics (OBD)
- malfunction indicator lamp (MIL)
- data link connector and harness
Miscellaneous Parts used in the Above Systems
- hoses
- switches, sensors and solenoids
- gaskets and seals
- wires, harnesses and connectors
* major emission control components - see page 171
Federal Emission Warranty
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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Lotus Cars
Limited are pleased to explain the emission control system
warranty on your new, USA specification, Lotus Elise. In
California, new motor cars must be designed, built and equipped to meet the State’s stringent anti-smog standards.
Lotus must warrant the emission control system on your
Elise for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of
your car. Your emission control system may include parts such as the carburettor or fuel injection system, the igni
-
tion system, catalytic conver tor, and engine computer.
Also included may be hoses, belts, connectors and other
emission-related assemblies. Where a warrantable condition exists, Lotus will repair
your car at no cost to you including diagnosis, parts and labour.
MANUFACTURER’S WARRANTY COVERAGE
- For
3 years or 50,000 miles (whichever first occurs):
1) If your car fails a Smog Check inspection, all necessary repairs and adjustments will be made by Lotus to ensure that
your car passes the inspection. This is your emission control
system PERFORMANCE WARRANTY.
2 ) I f a n y e m i s s i o n r e l a t e d p a r t o n y o u r c a r i s d e f e c-
t i v e , t h e p a r t w i l l b e r e p a i r e d o r r e p l a c e d b y L o t u s .
This is your short-term emission control system
DEFECTS
WARRANTY.
- For
7 years or 70,000 miles (whichever first occurs):
1) If an emission related part listed in this warranty booklet specially noted with coverage for 7 years or 70,000 miles
is defective, the part will be repaired or replaced by Lotus.
This is your long term emission control system DEFECTS
WARRANTY.
California Emission Warranty
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CUSTOMER ASSISTANCELotus Cars Ltd. wishes to help assure that the Emission
Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you believe
you are entitled under the Emission Control Systems Warranty, or if you need additional assistance or information concerning
this warranty, you should contact: Lotus Cars U.S.A. Inc., 2236 Northmont Parkway, Duluth, Georgia 30096. If you cannot obtain satisfaction, you may contact: Air Re
-
sources Board, Mobile Source Division, 9528 Telstar Avenue, El Monte, CA. 91731.
7 YEAR/70,000 MILE EMISSIONS DEFECTS WARRANTY PARTS LIST
- Catalytic Converter
- Engine Management Electronic Control Module
- Throttle Body
- Exhaust Manifold
- Fuel Tank
- Fuel Level Sender and Seal
- IAC Valve
- Knock Sensor
- Intake Manifold and Gasket
- Fuel Pressure Regulator Valve
- Fuel Level Vent Valve
- Roll Over Valve
- Instrument Pack
- Main Harness
Califo rnia Emission Warranty
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INDEX
Access Panels, front service ................................................. 78
Accessories & Modifications, warnings .............................. 150
Air Cleaner Element ............................................................. 113
Air Conditioning ...................................................................... 61
Airbag Safety System ............................................................. 21
Alarm, car security ................................................................ 30
Alternator Belt ...................................................................... 114
Anti-freeze/Corrosion Inhibitor ............................................. 107
Anti-Lock Brake System (ABS) .............................................. 67
Audio Equipment ................................................................... 60
Auxiliary Power Socket .......................................................... 57
Battery ................................................................................. 129
Bodycare ............................................................................... 93
Brake Fluid Reservoir .......................................................... 110
Brake Pads ........................................................................... 111
Break-In, running-in .............................................................. 73
Bulb Replacement ............................................................... 142
Central Door Locking ............................................................. 37
Child Restraints ..................................................................... 26
Cleaning, bodycare ............................................................... 93
Coolant Temperature Display ................................................ 53
Cooling System ................................................................... 106
Dipswitch ............................................................................... 58
Doors, keys ............................................................................ 37
Engine Cover/Trunk Lid ........................................................ 79
Environment, care of ............................................................. 14
Fuel Level Display ................................................................. 52
Fuel Filling ............................................................................. 76
Fuel Requirement .................................................................. 75
Fuses ................................................................................... 135
Gear Lever ............................................................................. 71
Hazard Warning Lamps Switch ............................................ 55
Headlamp Alignment ........................................................... 139
Index
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Headlamp Flasher .................................................................58
Heating & Ventilation .............................................................. 61
Horn ...................................................................................... 60
Idle Speed ............................................................................. 73
Ignition Switch ....................................................................... 44
Immobiliser, engine ................................................................ 31
Inertia Switch ...................................................................... 135
Instrument Illumination .......................................................... 56
Interior Lamp .......................................................................... 41
Jacking Points, lifting you car .............................................. 148
‘Jump’ Starting ..................................................................... 133
Keys ...................................................................................... 29
Lighting Switches .................................................................. 54
Lights On Buzzer .............................................................. 40,55
Lubrication - Dipstick, engine oil level check ....................................... 99
- Engine Oil Change ........................................................ 100
- Oil Filter ......................................................................... 102
- Recommended Lubricants ............................................ 153
- Tran smission Oil ............................................................ 103
Mirrors ................................................................................... 40
Odometer .............................................................................. 53
Parking Brake ........................................................................ 70
Pedals ................................................................................... 66
Queen’s Award ..................................................................... 191
Roof, Hard Top ...................................................................... 85
Roof, Soft Top ....................................................................... 82
Safety Information ....................................................................
7
Seat Be lts .............................................................................. 18
Seats ...................................................................................... 17
Servicing ............... see separate Maintenance Record booklet
Sparking Plugs ..................................................................... 114
Speedometer .......................................................................... 51
Start Button, engine .............................................................. 45
Starting Procedure ................................................................ 72
Index
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The Queen’s Award for Enterprise
The Queen’s Award for Enterprise is the highest honour that
can be bestowed upon a British company and is the UK’s top award for business performance. The award is given annually
by Her Majesty The Queen and the winning companies hold it
for five years.
Group Lotus PLC and its staff were awarded The Queen’s
Award for Enterprise 2002 for the whole group’s outstanding achievement in international trade. Lotus Cars has sold its prestigious sports car models into over 30 countries around the
world and Lotus Engineering, which has been investing heavily in engine and chassis research, is regarded as one of the world’s
leading engineering consultancy groups.
The Lotus Elise now proudly displays The Queen’s Award
logo on the rear window. This logo symbolises the achieve
-
ments of Group Lotus over the last few years culminating in the company being given the Award in 2002 – the year of The
Queen’s Golden Jubilee.
The Queen’s Award scheme was introduced in 1966, originally
as The Queen’s Award to Industry before becoming known as
The Queen’s Award for Enterprise in 1999.
Her Majesty The Queen makes the Awards on the advice of
the Prime Minister, who is assisted by an Advisory Committee
that includes representatives of Government, industry and com
-
merce, and the trade unions. They are announced on 21 April,
The Queen’s personal birthday.
For more information about The Queen’s Awards, please see
www.queensawards.org.uk
The Queen’s Award
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