cooling LOTUS ELISE 2005 Owners Manual

Transmission Oil .....................................................103
Cooling System .......................................................
106
Anti-Freeze/Corrosion Inhibitor ...............................
107
Coolant Drain/Refill Procedure ................................
108
Washer Reservoir ...................................................
109
Wiper Blade .............................................................
109
Brake Fluid Reservoir ............................................... 110
Brake Pads ............................................................... 111
Brake Pipes and Hoses ............................................112
Air Cleaner Element ................................................. 113
Auxiliary Drive Belt ................................................... 114
Sparking Plugs ......................................................... 114
14. TIRES & WHEE
LS
Tires ................................................................ 115
Glossary of Terms .................................................... 115
T
ire Safety ................................................................ 115
Tire Care ................................................................ 117
Replacement Tires ................................................... 118
Tire Characteristics .................................................. 119
Winter T
ires .............................................................. 119
Tire Cha
ins ..............................................................120
Uniform T
ire Quality Grading ...................................120
Tire Placard
/Label ...................................................121
Steps
for Determining Correct Load Limit ...............122
Tire Ma
rkings ..........................................................123
T ire Inflator Aerosol .................................................
124
Wheels ...............................................................
126
Wheel Bolts .............................................................
126
Wheel Alignment & Tire Balance .............................
126
Wheel Replacement ................................................
127
15. ELECTRICAL
Battery ...............................................................129
Battery Access ........................................................
129
Disconnecting the Battery .......................................
129
Reconnecting the Battery ........................................
131
Battery Charging .....................................................
131
‘Jump’ Starting ........................................................
133
Electrical Accessories ...................................................
134
Inertia Switch ...............................................................
135
Fuses ...............................................................
135
Contents
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will also disable the engine coolant pump and result in rapid overheating; stop the engine as soon as it is safe to do so, and
summon assistance. If the drive belt is intact and the cooling
system unaffected, it may be possible in favourable daylight conditions, to drive a short distance to a repair facility, but do not, under any circumstances, allow the battery to become
completely discharged by continuing to drive.
Engine Malfunction Indicator Lamp
The engine Malfunction Indicator Lamp (MIL) is provided to
warn the driver that the engine management system has de
-
tected a fault which may result in increased noxious emissions from the exhaust. In order to minimise emissions and potential
engine damage, various operational limitations may automati
-
cally be applied. i) If the MIL lights continuously whilst driving, immediately reduce
speed and adopt a moderate driving style. Seek dealer advice
without delay and avoid all unnecessary journeys.
ii) If the MIL flashes, an engine misfire has been detected which is likely to cause overheat damage to the catalytic converter.
Slow down immediately and be prepared to stop.
- If the MIL then stops flashing, and is lit continuously, proceed with caution and seek dealer advice.
- If the MIL continues to flash, stop the car as soon as it is safe to do so, and switch off the engine. Seek dealer advice.
NOTICE:
Continuing to drive the car with a flashing MIL may
cause overheat damage to the catalytic converter, possible en
-
gine damage, increased emissions, and impaired fuel economy and driveability.
In order to comply with emissions regulations, data regarding
activation of the MIL is recorded in the engine electronic control
-
ler, and may be downloaded by Lotus dealers.
Security/RPM Tell Tale The security tell tale is located at the top of the tachometer
display, and indicates the status of the immobiliser and alarm.
• Tell tale out; engine is mobilised, and the alarm is off.
• Tell tale flashing; engine is immobilised, or alarm is armed
and engine immobilised.
For full details of the car security system, refer to the earlier
section ‘Car Security’.
Instruments & Switches
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When only a single segment remains, representing approxi-
mately 1.3 U.S. gall. (5 litres), the amber low fuel tell tale will
flash. Refuel at the next opportunity.
NOTICE: Do not allow the tank to run completely dry, as this may damage the catalytic converter and fuel pump. This may
affect the terms of your warranty.
Coolant Temperature Display The engine coolant temperature will be displayed at the bot
-
tom right hand corner of the panel as soon as the temperature reaches 162°F. The running temperature will fluctuate a cer
-
tain amount as the operating conditions change, and during periods of idling or in heavy traffic, the temperature may rise to
over 212°F, with the cooling fans switching on at half speed at
approximately 208°F and at full speed at approximately 217°F.
The temperature display will flash at temperatures over 226°F to prompt closer monitoring by the driver of high temperatures.
The pressurised cooling system has a boiling point of over 248°F.

If the temperature approaches this level then the driver should be concerned. If this should occur, allow the engine to idle for a
few minutes whilst monitoring the temperature, and if it continues to rise, switch off and seek qualified assistance.
NOTICE: After a heavy snowfall, ensure that the radiator cooling
outlet grilles in the front body are cleared of snow before driving
the car, or overheating may occur.
Odometer An odometer (total distance recorder) reading is displayed at
the bottom left hand corner of the panel.
Trip Recorder A trip distance recorder is provided at the top left hand corner
of the panel. In order to zero the trip display, switch on the ignition, and
press for a moment (less than 1 second), the small button
on the steering column shroud ahead of the ignition switch.

This dual function button also controls the panel illumination
- see ‘Instrument & Switch Illumination’.
Instruments & Switches
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Air Re- circulation The air supply for the interior climate system is normally drawn
from both the car interior and from the fresh air intake duct ahead
of the engine cooling radiator. When the re-circulation button is pressed, the fresh air intake port is closed down to provide 90%
re-circulation air supply to the cabin interior. The re-circulation
facility should be used when maximum refrigeration is desired.
The tell tale in the switch button will light up blue when the
circuit is active.
Heater Temperature With the left hand rotary control turned fully counterclockwise,
no heating is provided. If cooled air is required, use this tem
-
perature position in conjunction with air conditioning. Turning the control progressively clock wise provides in
-
creasing levels of heat until at the fully clockwise position, maximum heat is supplied.
Fan Speed The centre rotary switch provides three fan speeds to boost air
circulation. Turned fully counterclockwise, the fan is off; Turning
the switch progressively clockwise operates the blower fan at increasing speed in three steps. Note that the fan operates only with the ignition switched on.
Heating, Ventilation & A.C.
62
p99
TemperatureFan SpeedDistribution
Air conditioning Air re-circulation

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FootbrakeVentilated disc brakes are fitted to all four wheels of the
Elise. These are operated by separate front and rear hydraulic
circuits, supplied from a tandem master cylinder with vacuum
servo. Anti-lock control is provided by a microprocessor based

electro-hydraulic unit, integrated into the base braking system. The braking system is designed to provide good pedal feed
-
back, with efficient disc cooling to inhibit brake fade. With a
new car, or new brake system components, maximum braking
efficiency will be achieved if, for the first few hundred miles, needless heavy braking is avoided. Allow the brake pads and discs to ‘bed in’ fully before using the brakes to their full potential.
Pedal effort will reduce as the brakes are bedded in, and as they
are warmed from cold to normal working temperature. Note that
the hard grade pad material may give rise to a certain amount of brake noise under some conditions; such noise is not harmful
and does not affect the life or efficiency of the brakes.
WARNING:
• After driving through a ford, or a flooded road, some loss of braking response may be experienced until the brakes
have dried out. As soon as it is safe to do so after such an encounter, apply the brakes until normal operation
is restored. Failure to do so may result in an accident in
which you or others may be killed or seriously injured.
• The brake assistance servo uses vacuum supplied from the engine intake plenum, such that assistance is avail
-
able only when the engine is running. Never coast down
-
hill with the engine stopped. If this situation accidently arises, avoid repeated application of the brakes, or the
stored vacuum supply will be rapidly used up. Greater
pedal pressures will be required. This may adversely affect performance of the brakes which may result in an
accident in which you or others may be killed or seriously
injured.
Anti-lock Brake System The Anti-lock Brake System (ABS) is used to optimise brake
performance in extreme conditions and reduce the potential
for any wheel to lock up. Under most conditions, the maximum braking force is provided by a wheel which is rotating at about
90% of road speed. Apart from the likelihood of increasing the
Driving Controls
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Cooling SystemThe engine cooling system uses a header tank to ensure that
the system remains completely filled, and also to accommodate
expansion of the coolant with increasing engine temperature.
The tank is mounted at the left hand side of the engine bay, and is fitted with a 108 kPa (15 psi) pressure cap to raise the boiling point of the coolant to over 120°C (250°F).
WARNING:
• Do NOT attempt to remove the pressure cap or air bleed plug from the header tank when the engine is warm
as serious scalding could result from boiling water

and/or steam.
• Coolant is hazardous to your health and may be fatal

if swallowed.
• Keep coolant out of reach of children.
• Coolant is hazardous to animals and may be fatal if

swallowed. Clean up spilled coolant and do not leave in
open containers.
The level of coolant in the translucent header tank will rise
as the engine warms up, and fall as it cools down, and under
normal circumstances it should not be necessary to add any
coolant to the system between services. If overfilled, the excess
coolant will be ejected when the engine is warm. If under filled, overheating may result.
Servicing & Maintenance
106
ohs130
Air bleed plugCoolant header tank cap

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As a precaution, every week when the engine is completely
COLD, and without disturbing the filler cap, check that the level of coolant in the translucent tank is between the ‘FULL’
and ‘LOW’ marks moulded on the front of the tank. If topping
up is required, wait until the coolant has fully cooled before
turning the cap a quarter turn counterclockwise and allowing any remaining pressure to escape. Only then may the cap be
completely unscrewed. In order to maintain protection from freezing damage and
metal corrosion, use only an approved coolant mixture (see below) to top up the tank to the ‘FULL’ mark. Refit the cap, and
turn clockwise until the leg on the cap locates in the slot at the
front of the tank.
NOTICE: If the cap is removed when the engine is warm, the coolant may boil and a small coolant loss may occur. The com
-
pletely cold header tank level should be checked at the first subsequent opportunity.
Cooling Fans
: Two cooling fans are fitted below the radiator in
the air intake duct. The fans are energised at high coolant tem
-
peratures, or when the air conditioning (if fitted) is selected. The
fans will also run if certain types of engine fault are detected, and
may operate during a 20 minute period following ignition switch off to prevent ‘hot soak’ boiling. An electric coolant circulation pump may also be heard running during this period.
WARNING: Keep hands, tools and clothing away from the radiator
cooling fan area, as personal injury could result from the
fans starting up without warning.
At service intervals, the air duct and matrices of the engine
cooling radiator, a.c. condenser and oil coolers, should be
checked externally for clogging by insects, leaves or other debris,
and if necessary, a water jet used to clear the finning. Take care not to damage or distort the delicate finning of the radiator or
the cooling performance will be degraded.
Anti-Freeze/Corrosion Inhibitor It is most important that the correct coolant specification is
used in order to inhibit boiling and protect the engine and heat
Servicing & Maintenance
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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
-
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
-
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
-
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
-
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.
Servicing & Maintenance
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NOTICE: Using incorrect wheel/tire equipment can also cause problems with wheel bearing life, brake cooling, speedo and
odometer calibration, headlamp aim, ground clearance and tire
clearance to the body.
WARNING: Dirt or corrosion on a wheel or hub mounting flange or
wheel bolts, can result in the wheel bolts coming loose.
The wheel could come off and cause a crash in which you and others could be killed or seriously injured. Thoroughly
clean these components or fit new Lotus approved replace
-
ments before fitting a wheel. Never use oil or grease on the wheel bolts or hub threads.
If you do, the bolts could come loose and the wheel could
come off, causing a crash in which you and others could be killed or seriously injured. Using incorrect wheel bolts, or the wrong tightening
torque could cause the bolts to come loose and the wheel to come off, resulting in a crash in which you and others could be killed or seriously injured. Use only the correct Lotus
approved wheel bolts tightened to 77 lbf.ft (105 Nm).
NOTICE: Improperly tightened wheel bolts, or dirt on the wheel
to hub mounting face can cause brake pulsation and judder, and damage the brake discs. To avoid expensive brake repairs,
ensure complete cleanliness on assembly and tighten the wheel
bolts in a diagonal sequence to the correct torque.
For advice and information on lifting the Elise, refer to ‘Lifting
Points’ on page 148Tires & Wheels
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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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