service LOTUS ELISE 2005 Owners Manual

10. DRIVING CONTROLS
Foot Pedals .................................................................
66
Footwell Carpets .............................................................
66
Clutch Pedal .................................................................
66
Footbrake .................................................................
67
Anti-Lock Brake System .................................................
67
Parking Brake .................................................................
70
Gear Lever .................................................................
71
11. STARTING PROCEDURE & ENGINE BREAK-IN
Starting a Cold or Warm Engine .....................................
72
Idle Speed .................................................................
73
Engine Break-In ..............................................................
73
Engine Special Features .................................................
74
12. EXTERNAL OPERATIONS
Fuel Requirement ...........................................................
75
Fuel Filling .................................................................
76
Front Service Access Panels ..........................................
78
Engine Cover/Trunk Lid ..................................................
79
Child Entrapment ......................................................
80
Removable Roof Concept ...............................................
81
Soft Top Roof Fitting ..................................................
82
Soft Top Roof Removal .............................................
84
Hard Top Roof Fitting ................................................
85
Hard Top Roof Removal ............................................
90
13. SERVICING & MAINTENANCE
Bodycare .................................................................
93
B
ody Features ...........................................................93
Paint Care .................................................................
94
Ventilation .................................................................
94
Paintwork Polishing ...................................................
95
Washing .................................................................
95
Soft Top Roof ............................................................
96
Windscreen Cleaning ................................................
96
Alloy Road Wheels ....................................................
96
Upholstery Cleaning ..................................................
97
Seat Belts Cleaning ...................................................
97
Footwell Cleaning ......................................................
97
Owner Maintenance ........................................................
98
Engine Oil Level Check .............................................
99
Engine Oil Change ..................................................
100
Oil Filter ...............................................................
102
Used Engine Oil ......................................................
103
Contents
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NOTICE: DO NOT push or tow start the car; or turn off the igni-
tion at engine speeds above idle; or run the fuel tank dry: Any of these actions may damage the catalytic converter.
Before driving the car:
• Check tires for damage, wear and proper inflation.
Under-infla-
tion causes increased rolling resistance and uses more fuel.

(Please refer to the section in this handbook on tires, page 115).
• Check all windows, mirrors and lights are clear and unob
-
structed and all lights are correctly working.
• Check that the engine cover and front body access panels
are correctly latched;
• Adjust the seat and mirrors, and familiarise yourself with

the controls.
• Check all instruments and warning lamps (‘tell tales’) are reading correctly.
• Ensure that both driver and passenger are properly restrained
by their seat belts.
Care of the Environment By virtue of its light weight, simple content, constructional
process and fuel efficiency, the Elise has a low environmental im
-
pact compared with many road cars. All drivers should, however,
be aware of the effect of motor car exhaust emissions on the
environment and drive in a way which minimises pollution by:
• Anticipating traffic flow to avoid needless acceleration

and braking.
• Using the highest suitable gear.
• Switching off rather than idling for long periods.
• Driving off as soon as it is safe to do so; it is not necessary or beneficial to the engine to allow extended idling from cold.
• Having the car serviced regularly as a poorly maintained car will use more fuel; have any engine faults attended to imme
-
diately.
• Considering the need to use the car for very short journeys.
The emissions produced by an engine are many times greater
when cold than when warm.
Safety Information
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• Drivers airbag circuit;
• Passenger airbag circuit;
• Seatbelts pre-tensioner circuit;
• Internal componentry of the sensor and diagnostic module.
As a bulb and circuit check, the tell tale will light briefly when
the ignition is switched on, and then go out. If the lamp lights at any other time, a fault in the airbag system is indicated, which
should be rectified without delay by your Lotus dealer.
WARNING: If the airbag tell tale does not light up as the ignition is
turned on, or remains lit for more than a few seconds, have
the fault rectified immediately by your dealer. Ignoring the
tell tale can result in serious injury or death if the airbags do not inflate when needed.
Airbag Deployment If a crash or collision causes the airbags to inflate, you may
see what looks like smoke, but is actually powder from the airbag
surface used to aid smooth deployment. Although the powder is not harmful, people with respiratory problems may experience
some temporary discomfort. If this occurs, get out of the car if possible as soon as it is safe to do so. After airbag deployment, the airbags, seat belt tensioners
and electronic control unit must be replaced by a Lotus dealer
or other suitably qualified organisation. Component parts of the airbag system are located in various
sites around the car. Any technician working on the car should be advised that the car is fitted with airbags to allow suitable
precautions to be taken.
WARNING:
• For up to 20 seconds after the ignition has been turned off and the battery disconnected, an airbag can still

inflate if improper servicing occurs. You can be injured
if you are close to an airbag when it inflates.
• Airbag system components should be serviced only by an authorised Lotus dealer. Do not work on the airbag
system yourself.
• The disposal of used airbag units is subject to stringent
Seating & Safety Restraints
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efforts are likely to reduce during the break-in process.After 600 miles (1,000 km) have been covered, full throttle
and/or maximum rpm may be used for short periods, but not
until the first ‘After Sales’ service has been carried out should
full car performance be exploited. Note that various operating parameters are continuously
monitored and recorded in the engine electronic controller. This
data may be downloaded by Lotus dealers on demand to assist
fault diagnosis and identify vehicle misuse.
Tires:
New tires also require a short ‘break-in’ period before
providing optimum grip.
Engine Special Features The engine of the Elise is designated V VTL-i for ‘Variable
Valve Timing and Lift - intelligent’. Using microprocessor control, the inlet camshaft timing is advanced or retarded according to
immediate operating conditions, and the lift of both inlet and
exhaust valves is increased at high engine speed. This technol
-
ogy is used to provide high power output whilst retaining good
low speed response.
Starting & Engine Break-In
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EXTERNAL OPERATIONS
Fuel Requirement USE UNLEADED PREMIUM GR ADE GASOLINE.
Use only unleaded gasoline meeting ASTM specifications.
Use of fuels not meeting ASTM specifications could cause poor performance and increase emissions.
For optimum car performance and fuel economy, the use
of super or premium unleaded gasoline, with a minimum
octane rating of 91 (RON+MON)/2 is recommended. Where
super or premium fuel is not available, the Elise will operate
satisfactorily on unleaded gasoline having a minimum rating
of 87 (RON+MON)/2, but car performance and economy will be reduced. Using fuel with a lower octane rating may cause knocking
(pinking) which, if severe, can cause serious engine damage.
Light knocking may occasionally be heard for short periods when accelerating or driving up hills, and this should cause no concern,
although using a lower gear would be advised. If, however, you hear persistent heavy knocking when using the specified fuel,
consult your dealer without delay.
The use of good quality fuels containing proper detergent ad
-
ditives is advised for good performance and emission control.
NOTICE: Do NOT use leaded fuel: damage caused by the use of leaded or other improper fuel is not covered by the New Car
or Emission Control System Warranty. The effectiveness of
the catalytic converter decreases after as little as one tankful
of leaded fuel. Also, the car is fitted with a fuel injection system
which includes an oxygen sensor. Leaded fuel will damage the sensor, and cause emission control to deteriorate.
Gasolines Containing Alcohol - Some gasolines sold at service stations contain alcohol although they may not be so identified.
Use of fuels containing alcohol is not recommended, unless the nature of the blend can be determined as being satisfactory.
Gasohol - A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in the Lotus Elise. If driveabil
-
ity problems are experienced as a result of using gasohol, it is recommended that the car is operated on gasoline.
External Operations
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REMOVING ACCESS PANEL
Front Service Access PanelsThe front body has two removable access panels to allow
servicing of the brake/clutch fluid reservoir and main fusebox.
To remove an access panel:
Use the hexagonal key supplied
in the car tool kit (in the battery cover rear pocket), to release
the single threaded fastener securing the outboard corner of
the panel, and withdraw the panel from the two locating holes in the front body spine. Guard against the lightweight panel being blown away and
damaged by a strong wind.
To refit a panel: Hook the extended lip on the front edge of the panel beneath the rear edge of the louvre panel before engaging
the two locating pegs on the inboard side of the access panel
with the holes in the front body spine. Fit the single screw at
the outboard corner of the panel into the captive nut in the body,
taking care not to cross-thread or overtighten the screw. Re-stow
the hexagonal key in the tool kit.
WARNING: Ensure the access panels are refitted and properly se
-
cured before driving.
External Operations
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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
-
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
-
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
-
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
-
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.
Servicing & Maintenance
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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
-
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
-
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
-
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
-
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.
Servicing & Maintenance
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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
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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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