ie Pe CRSA hed STAN ‘MOTOR SPORT SECTION XA - ELISE ‘Sub-Section Page Introduction xAL 2 190 VHPD Engine XA2 2 ‘Competition/Competition Style Seats & 6-Point Competition Hamess XA3 8 Roll-Over Bar Competition Reinforcement Kit XA4 1" Hand Held Fire Extinguisher XAS “4 Plumbed-In Fire Extinguisher XAG 6 Uniball Toe Link Kit XAT 7 Road Spring & Damper Set XAB 18 Front Hub Clamp Bolt Set XA9 2 Adjustable Front Anti-Roll Bar XAI0 22 Oil Cooler Kit XA 23 Battery Isolator Switch XA 26 Removable Steering Whee! xAI3 31 Stage 2 (135 bhp) Engine Tuning Kit XAG 33 Yokohama A038-R Competition Tyres XAIS 35 340R 340 PS/Tonne Pack XA16 36 340R Oil Cooler Kit XAI7 40 Goodridge Brake Hose Set XAIB 42 Sth-Point Seat Hames Kit XA19 42 Rear Racelight Conversion Kit XA20 43 Tonneau Cover xA21 44 340R Exchange 190 bhp ECM XA22 48 340R Tach Timer Level 1 XA23 48 340R Competition Roll Over Bar XA24 50 omnn (ny Pagetrei fog Lotus Cars is marketing a range of performance products for the Elise, aimed primarily at competition andlor track use of the vehicle. Some of the kits may be used alone, but others may be recommended for use only in conjunction with other complimentary kits. Using the car on the public highway with competiton parts fitted may contravene emission and/or noise regulations and invalidate insurance cover. In addition, the specification will be compromised in terms of comfort and refinement, and demand increased maintenance and service. In most cases, the standard vehicle warranty will not apply after the fitment of ‘off road’ or ‘competition’ oriented parts. %XA2-190 VHPD ENGINE ‘The 190 VHPD (Very High Performance Derivative) engine is designed for motorsport track use only, and ‘may not comply with emission regulations. The unit is based on the same 1.8 litre Rover’ series’ block as the standard engine, but with a revised cylinder head featuring new inlet and exhaust camshafts, solid tappets, and ew throttle bodies providing individual throttle butterflies for each cylinder and a competition type oiled foam aircleaner. The engine bottom end includes forged pistons, strengthened connecting rods and crankshaft, and a lightened flywheel. A reprogrammed ECM is an integral part of the package. The preferred fuel is 98 RON unleaded (‘Super Unleaded’), although 95 RON is useable. Oil recommendation is Mobil 1 5W/50 fully synthetic after running in on a good quality mineral oil, Output: Max. power; 190 ps @ 7,500 rpm Max. torque; 189 Nm @ 5,600 rpm The engine is supplied only as a complete assembly for competition use, and does not carry the normal vehicle or parts warranty. Inclided in the engine package are: Engine hares and new ECM with matched security 5AS module. Exhaust manifold (unchanged). Inlet manifold, throttle bodies and competition air fiter. Air fiter cil aerosol. Fuel rail and injectors. Alternator and auxiliary belt (unchanged). Lightened flywheel (no clutch) Engine mounted water rails. Oil fitter. Ignition coil, spark plugs and H.T. harness. The additional parts required in order to fit he VHPD engine, are contained in fiting kit A111E0034J, and comprise = Carbon fibre cold air box and trunking. Requires removal of boot bulkhead to accommodate the air box, and cutting down of the standard air fiter mounting plate for the trunking. The charcoal canister also requires removal, with a corresponding modification to the filler neck breather hose routing, - New throttle cable. - New fuel feed and return pipes with clips. + Crankcase breather pipe kit = Throttle cable 'U' bracket. = Cobra immobiliser bridging plug. Unless already so equipped, the later type closer finned (20 fp, instead of 16 f, radiator must also be ordered and fitted - A111K0021F. i.) engine cooling Additional parts strongly recommended: \n order fully to exploit the performance of the VHPD engine, it is strongly recommended to fit the following components: = Oil cooler kit (A111K00378). + Competition silencer kit (A111$0037S) and catalytic converter substitution pipe (A111S00488), Page 2 2000 / 03Te) RST edad Epes ince notes for fiting engine assembly 1. Remove complete power unit as detailed in Elise Service Notes sub-section EE.3. 2. Remove the transmission and clutch (sub-section QF.4). The standard friction plate and clutch cover can be fitted to the lightweight flywheel on the new engine. 3. New, longer, fuel feed and return pipes are needed to allow fitment of the new airbox: Parts. included in fitting Kit Fuel Feed Pipe AMiLe039S Fuel Return Hose AMIL6040S lip, fuel pipe support, tie wrap Aos2wes24F = 2 Clip, fuel pipe support, C clip Aos2Wess7F 2 Oetiker Clip, fuel return hose Bos2Ke06oF = Fit the new fuel feed pipe to the left hand end of the fue! rail, smearing the 'O' ring with silicone grease and tightening the two fixing screws to 4 Nm. Fit the retum hose to the RH end of the rail and secure with the Ostiker clip. Secure the hose using the two ‘C’vtie wrap clips to the header tank water hose as shown. Header tank water hose i Fuel return pipe a Fuel pipe clips 4, Remove the charcoal canister from the LH front of the engine bay and re-route Roll over valve _ the breather pipe from the roll over valve to vent to atmosphere at the RH engine mounting bracket. Re-routed breather hose Vented to y atmosphere ~~; /ie tus Service Notes Section XA 5. The mounting plate for the original air Fuel filter cleaner and fuel filter must be cut down to allow the new air intake trunking to be fitted. 6. The new carbon fibre airbox draws cold air from the LH air intake: Parts Requi Carbon Fibre Aibox A111E0020S 1 including: Ducting & Clips. A111€00228 1 Adaptor. Adaptor A111E0023K 1 Remove the new air cleaner element from the backpiate by releasing the four socket head screws. Oil the filter ele- ‘ment with the ITG aerosol to give an even coverage, then gently massage the Gil into the depth of the foam. Feed the air cleaner element into the new airbox, ft the airbox onto the backplate, and secure the airbox and cleaner with the four screws. Remove the existing profile adaptor from Ducting tor and ducting, Airbox Foam air cleaner. element Airbox fixing. Page 4@ URSA rece) Tol Cornea 7. Fitnew engine breather hoses: Parts Required Breather Hose Kit A1t1E0035) 1 ‘Assemble the cam cover breather pipe assembly as shown and connect tothe two cam cover spigots and airbox grommet. Grommet A082L6181F ‘Adaptor AI11E6153S Hose A111E0029S ‘T-plece A111E6152S- Hose A111E0032S Clip ATI1E6154S Clip ATI1E6155S Hose AI11E6151S 8, If the oil cooler kit is to be fitted, replace the oil fier housing with the new item, and fit the 90° adaptor for the oil pressure switch, 9. Rett the clutch and transmission (sub-section QF.4) to the engine, and fit the complete power unit back into the car (sub-section EE.3). Note that the luggage bay bulkhead is not re-ftted. 10. Fit the new throttle cable A111J01408 to the engine, connecting to the linkage between the two throttle bodies, and route as previously to the pedal box. 11. Atthe pedal box, check the specification of 'U' bracket attaching the throttle linkage to the pedal. The later type (introduced January '98) bracket must be fitted which is both thicker and wider. Check also that the bracket is correctly assembied and hooked through the pedal ex- trusion. Throttle pedal Page 5re) Eade ole Say Oldtype; 1.6 mm thick, 19mm wide. Later type; 2.0 mm thick, 15 mm wide. (C111J0046F) Wnecessary, rivet the later type bracket to the pedal using a 3/16" dia. 1/2" reach pop rivet. 12, Also at the pedal box, check the specification ofthe throttle linkage relay lever. The later type (B111J0045E introduced February '98) must be fitted which is notched to allow for clearance with the mounting plate fixing with the greater required lever travel. Alternatively, the existing lever may be modified as shown below: Fit notched side to rear (driver) Radius 12.5mm 20mm { Adjust the cable at the throttle body abutment to allow full throttle to be attained. If necessary, adjust the Pedal upstop and pedal pulirod length. Ensure that the pedal downstop is set to protect the cable from strain at full throttle. 13. The engine is supplied with a new ECM together with a matched security SAS module. If the caris to be tused in competition, itis recommended to disable the passive immobilisation by disconnecting the driver's door switch. The alarm may stile armed on demand, but will not be triggered by the driver's door. ' the car is equipped withthe optional Cobra alarm system, passive immobilisation can be overridden by unplugging the immobiliser module and substituting bridging plug A111M0123S. Cobra immobiliser module Engine ( management ECM Antictamper cover Page 6ie tus Service Notes Saree 16. Unless a 20{.p.i. radiatoris already fitted, replace the 16 f.p.i. radiator with the later type. Parts Required Radiator, engine cooling, 20 f.pi. AittKoo21F Refer to sub-section KF.4 for fitting details. tenance Instruction Note - Engine Air Filter M The ITG foam air cleaner element supplied as part of this package requires the following maintenance procedure to ensure efficient results: 1. The new fiter element must be oiled before use (see installation procedure). 2, The filter must be cleaned regularly, dependent on operating conditions. Cleaning can be carried out Using a bath of petrol, or with liquid detergent and warm water. Rinse in warm water after cleaning. Do not use hot water. After cleaning, the fiter should be allowed to dry thoroughly. Do not use a high pressure air line, or a hot air blower. 3. After cleaning, the filter must be re-ciled. Use the ITG dust retention aerosol to spray a good covering of oil all over the element, then gently massage the oil into the depth of the foam. IMPORTANT: If the filter is not oiled thoroughly some fine dust may work through the filter. ‘Pagei) Pe CRA Ley Sa oe XA. MPETITION/COMPETITI \TS & 6-POINT COMPETITION Hi The Competition Seat is made by Corbeau specifically for the Elise for race track use, and features Prominent shoulder ‘wings’ and raised side bolsters designed to provide maximum lateral support in racing Conditions. Four point multi-position mounting brackets connect the seat to new seat mounting rails which use the original chassis fixing holes. A wide range of seat position, height and tit is available, but once chosen is. Rot readily adjustable. Note that the seat needs to be angled towards the car centreiine (as does the standard seat) and uses different fixing holes in the inboard and outboard rails. The seat and mounting rails are de- signed for use with the 6-Point Competition Seat Belt Hamess, in conjunction with the Roll Over Bar Reinforce. ment Kit. Only one Competition seat can be fitted, as a similar passenger seat would result in a clash between the seat back ‘wings’. However, a Competition Style passenger seat is available, which uses the standard seat shel, trimmed to match the Competition seat and modified to allow fitment of the competition seat belt har- ness. Alternatively, a pair of Competition Style seats may be fitted using either the standard 3-point inertia reel belts, or, in conjunction with the roll over bar reinforcement kit, the 6-point Competition Hamesses. The ‘Kruss’ Competition Harness uses 70mm wide shoulder straps wrapped around the roll over bar Feinforcing frame, 70mm lap straps and 50mm crotch straps, all of which plug into a single buckle with a bi- directional lever release. The installation of the harness is illustrated overleat for both seat types. Pay particu- lar attention to the threading of the shoulder straps through the adjuster buckle, which should be positioned close up against the reinforcing bar. Reducer studs are supplied with the hamess kit and are to be used for the lap strap anchorages on only the Competition Style seat, Recommended seat and seat belt fitment combinations are as follows: 1. = Competition Driver's Seat (A111V6034S) 1 off - Competition Style Passenger Seat (A111V6035S) 1 off Roll Over Bar Reinforcement Kit (A111A0245/68) 1 off (LHD or RHD) + 6-Point Competition Seat Belt Harness (A111U03788) 2 off, 2. = Competition Style Seat (A111V6035S) 2 off - Roll Over Bar Reinforcement Kit (A111A0245/6S) 1 off (LHD or RHD) + 6-Point Competition Seat Belt Harness (A111U0378S) 2 off 3. = Competition Style Seat (A111V6035S) 2 off (using standard 3-point seat belts) Note that fitment of the Roll Over Bar Reinforcement Kit precludes the use of the standard 3-point belts, and that the Competition Seat Belt Hames is not approved for toad use. Consequently, only option (3) above is suitable for road use. Competition Harness Shoulder (& crutch) Strap Det Belt looped back Roll bar'A’ through buckle frame tube (this threading also applies to crutch strap) Page 8Section XA a) Pee SA cedie Lotus Service Notes Sree ITION Special stud Page 10,XA - ROLL-OVER BAR COMPETITION REINFORCEMENT KIT This kit is designed to provide additional bracing to the roll-over bar for competition use, and allow the fitment of the 6-point competition seat belt harness (see sub-section XA.2). The standard 3-point inertia reel seat belts cannot be used with this kit. Note that the roll bar fairing and audio speaker panels must be removed cr modified, and that some driling of the chassis is required to fit the forward bracing strut. Description Part Number ay Roll-Over Bar Competition Reinforcement Kit, LHD AI11A0245S 1 Roll-Over Bar Competition Reinforcement Kit, RHD. ANt1A0246S 1 Comprising: ‘A’ Frame, roll-over bar reinforcing AN11A02848 1 Bolt, 7/16" UNF x 25, 'A' frame to roll bar base ArtiW2183F 2 ‘Washer, 7/16" nes ‘A075W4029F 2 End Spigot, hamess bar to roll bar A111A0224S 2 Bolt, M10 x 75, end spigot to roll bar ‘A075W2059Z 2 Washer, M10 oe A075W40372 2 Bolt, M8 x 50, harness bar and bracing bar toend spigots -- AO79W1044F 4 Washer,MB 0" "OH Ht A075W4079F 4 Nut, M8 mw A907E6284F 4 Bracing Strut, roll bar to footwell 111402395 1 "U' End Spigot, brace to roll bar, RHD/LHD A111A0226/7 1 Bolt, M12 x 80, 'U' end to ‘A’ frame A082W2157F 1 Washer, M1200" " A0B2W4154F 1 Corer Piate, bracing strut to floor, RHD/LHD A111A0237/8S 1 Reinforcing Plate, comer plate to floor 111402448 1 Screw, M8 x 20, pan pozi, corner plate to floor AO7SWS095F 2 Washer, MB" TT A075W4079F 2 Nut, MB, she ASO7E6284F 2 Setsorew, MB x 16, comer plate to chassis side rail A075W1036Z 2 Washer, MB ° AO7SWw4079F 2 Nut, M8, nor ASO7E6284F 2 Grommet, chassis side rail access hole A111A6003F 1 Fitting Procedure 1. If fited, remove the following: + Roll bar fairing and rear window; + Both audio speaker panels; - Both inertia reel lap and diagonal seat belts; = Passenger footrest Remove the end spigots from the ‘A’ frame harness bar, and fit the ‘A’ frame into position. Locate each bottom end of the frame with a hex. head bolt and washer to the existing inertia reel fixing point. Insert the end spigots into each end of the harness bar, ang fit the fixing bolts to the roll hoop and harness bar. Tighten the ‘A’ frame bottom fixings 1o 33 Nm, the harness bar end spigots to rall hoop to 45 Nm, and the hamess bar to end spigot through belts to 22 Nm, Remove the nut and washer trom the passenger side front lower wishbone rearmost pivot bolt, and fit the bracing strut comer plate over the end of the pivot bolt into the comer of the footwell, Mark the four fixing hole positions in the corner bracket against the chassis before removing the bracket and drilling the marked holes 9 mm diameter. For access to the comer plate fixings inside the chassis side rail, it is necessary to cut an access aperture in the underside of the chassis rail. With a centre marked as shown in the diagram, use a hole cutter or similar tool to cut a 35mm diameter hole and remove the sharp edge. Page 116. Fit the corner plate fixings, using the reinforcing plate on the underside of the floor, and tighten the fixings inthe following order: = Wishbone pivot bolt; 45 Nm at normal ride height = MB fixings; 22 Nm Fit the access grommet in the chassis side rail underside, Slide the 'U' end spigot onto the bracing strut, and engage the bracing strut front end into the comer plate at the same time as positioning the 'U' bracket over the roll hoop and ‘A’ frame apex. Fit and tighten the bolt clamping the 'U' bracket to the ‘A’ frame. Mark the position of the top and bottom holes in the 'U' bracket and comer plate tubes against the strut spigots. Release the 'U' bracket from the 'A’ frame and hoop, and withdraw the bracing strut. Drill the marked holes in each spigot to 9 mm diameter. Refit the bracing strut and ‘U' bracket, and insert the MB x 50 bolts through each strut end spigot. Tighten the M12 'U' bracket to'A' frame fixing bolt to 77 Nm and the MB end spigot bolts to 22 Nm. 10. Fit the 6-point seat belt harnesses as detailed in sub-section XA.2. Page 12i OES Ley ae. XAS- HELD FIRE EXTINGUISHER - 00; Recommended Fitting Instructions It is recommended that this extinguisher is mounted ahead of the passenger seat, fixed to the cockpit floor crossmember as detailed below: 1. Mark the positions of the two fixing holes in the crossmember as shown in the diagram. 2. _ Drill the two holes 9.0 mm diameter through only the top surface of the crossmember. Insert the two Rivnuts and use an M6 threaded puller tool, or appropriate M6 slave screws to crimp the ‘two Rivnuts into position, 4, Fit the extinguisher mounting bracket using the two countersunk M6 screws provided, and clip in the extinguisher. Chassis side rail Extrusion overlap edge 23mm Drill both holes Oa 3am diameter Page 141) ee ESA eked SC XA - PLUMBED IN FIRE EXTINGUISHER KIT - A111TO004S The illustration overleat shows the suggested layout ofthis fire extinguisher kit for use in the Lotus Elise. The bottle is secured to the passenger floor cross member using threaded inserts. - _ Arelease handle is mounted in the fascia, and externally on the front wing Extinguisher nozzles are mounted in the cockpit and at both sides of the engine bay. Pay close attention to any fitting instructions supplied with the kit, and check any specific requirements of competition events, Page 15ne) ee ESTA aoe ode) See Page 16wa pee STA Od SECA IT -A111001275 For competition use, especially if slick tyres are to be used with the associated increase in suspension loadings, it is recommended to replace the rear suspension toe control links with uniball type links, complete with brackets which support both ends of the pivot bolts, and provides additional strength to the chassis and hub carrier fixings. This kits designed to be used in conjunction with the Road Spring & Damper SetA111C0138S, Using the lowered ride height (100/110mm) as detailed in sub-section XA.8, The correct bump steer character- istic is not attainable at the standard ride height. Atthe inboard, chassis, end of the link, a steel bracket supports the rear end of the pivot bolt, and requires that the chassis be drilled to accept the four M6 screws fixing each of the brackets. Locate the bracket using the pivot bolt before marking up the four fixing hole positions on the chassis rear subframe. At the outboard end of the link, a milled aluminium bracket is bolted to the bottom of the hub carrier, utilising two of the lower ball joint plinth fixings. The pivot boit uses a sliding sleeve in the lower leg of the bracket to avoid any bending stress in the bracket when the bolts tightened. Note that each side of each of the Uniball joints must be faced by the smaller end of a conical washer in order to allow full articulation of the joint. stack of six shim washers is provided at the outboard end of the link, to be distributed above and below the Uniball in order to adjust the joint height and attain the desired bump steer characteristic. The default setting of the stack is for one washer above the joint, and five below, but for fine tuning of the toe curve refer to Service Notes sub-section XA8 ‘Support bracket, toe link to chassis Uniball toe link Conical spacer washers Shim washers, Mounting bracket, bump steer Uniball link to hub adjust carrier Unibalt wa 1999 /N1 Page 17Le ade Slee. XAB sPRING & DAMP| At1C01; Road springs and dampers are available as a vehicle set, designed to be used with a lowered ride height fortrack use. The front springs are uprated from 27.5 N/mm to dual rate 25/40 Nimm springs, and the rears are Uprated from 40 to 50 N/mm. All four fixed calibration Koni dampers are both stiffer and shorter and feature different bump stops and adjustable spring platforms (without lock rings) to allow setting of ride height and corner weighting. Also included, for use on cars prior to their introduction at VIN W 3580 (approx.), are stronger top rear damper mounting brackets with repositioned (0mm higher) damper holes, together with load spreading clamp plates to fix the brackets to the chassis. The pair of steering rack positioning plates are provided in order to maintain the desired bump steer characteristic if the lowered ride height is used. Additional parts recommended to be fitted with this kit are: - Front hub bearing clamp bolt set - A111C0137S (applicable to cars prior to VIN: V 1830 - Sept:'97) = Rear Uniball toe link kit -A111D6127S - Adjustable, uprated front anti-roll bar - A111C01348. The springs, dampers and rear top damper mounting brackets with spreader plates, are direct replace- ments for the standard parts, The dual rate front springs are fitted with the close coiled end lowermost. The recommended mid-laden ride height (2 people, 1/2 tank fuel) to be used with these springs and road tyres is as follows: Front: 100 mm below front end of chassis siderail (standard setting 140 mm). Rear. 110 mm below rear end of chassis siderail (standard setting 140 mm), At the lowered ride height, the steering rack should be repositioned by removing the raok fixings from the front of the footwells, driling out the pop rivets retaining the standard (5 notch) rack height setting plates, and fitting new (10 notch) plates A111H0021F. Refit the rack fixings using a suitable threadlocking compound, and torque tighten the M8 bolts to 27 Nm, and the M10 bolts to 45 Nm. Steering rack Stee! reinforcement channel (bonded) assembly Height setting plate M10 fixing bolt MB fixing bolt Pop rivet Chassis crossmember Page 1999 /01At the lowered ride height, the suspension geometry should be set as follows: Subjoct Speciication Tolerance Max. diference side/side Front Camber: -0.3" +0.1°,-0.2° 02° (std. ride height -0.1°) FrontCaster + 3.8" 202° oz Front Toe 0.2mm toe out overall = - 0, + 0.2mm RearCamber* = 2.0° £02" 02° (std. ride height: - 1.8°) Rear Toe 12mm toeineachside — -0,+0.2mm 0.2mm * In extreme cases, it may be necessary to machine the top ball joint plinth in order to attain sufficient negative camber. Rear Bump Steer he rear suspension toe-links are designed to steer the rear wheels in incremental amounts as the car rolls, with cornering forces, in order to produce the required handling characteristics. The general requirement is for the outside wheel to adopt a small amount of toe-in as it moves towards bump with roll. A shim stack is provided at the outboard end of the toe-link, by which the joint height, in relation to the wishbone pivots, may be adjusted. A basic stack dimension detailed below, will provide an approximately correct geometry, but in order to optimise the characteristic, accurate individual wheel alignment equipment (or a dedicated bump steer gauge) must be used to measure the toe change for each rear wheel. Lowering the joint height by 0.9 mm (1 shim washer) will increase the toe-in at 40 mm bump travel by approx. 0.2 mm, Refer to the graph below, and select a shim stack to provide a toe change on bump travel to lie within the tolerance band. Note that ifthe Uniball toe link is used, the shim stack is distributed above and below the joint. Tolerance band Bump 40 travel 30 > = 20 Displacement | from 10 - ride | height 0 (mm) | 10 -20 — -30 Droop travel -40 0.3 02 01 0 014 02 03 04 05 06 07 08 09 Increase in toe-in fa from base setting (mm) 1999 /01Ly tus Service Notes a elec Base Setting Standard toe link with female threaded pivot balls" 4x 1 mm shim washers Standard toe link with integral stud ball joints 3x1 mm shim washers Unibail toe tink: 3.x 1 mm shim washer above joint When changing ride height, the length of the toe link will need to be adjusted to maintain the specified rear toe setting, but the base setting of the shim washers is the same for standard (140mm) and race (100/110mm) ride heights. Note The standard toe-link with female threaded pivot balls requires a very specific assembly configuration with different bolt lengths and washers used for different shim pack thickresses. Refer to sub-section DE.4 for full details. If a car with this joint type is found to require more than 5 shim washers to produce the required charac- teristic, both outboard ball joints should be changed for the integral stud type, or Uniball inks fitted = Page 20 1999 /01core) Lotus Service Notes SC XA.9 - FRONT HUB CLAMP BOLT SET - A111C0137S. This set is applicable only to cars built before Sept.1997 (approx. VIN W 1830) with M12 front hub clamp bolts Ifthe car is to be used in a competition environment with the associated righ level of chassis loading, itis recommended to replace the front hub bearing M12 clamp bolts with an M76 clamp bolt set including thrust washers, which allows a substantial increase in the clamping force applied tc the inner bearing races. Cars from the above change point have been factory built with the M16 bolt set. Kit Contents Part no. ay Front Hub Clamp Bolt Set Att1001378 1 comprising: Bolt, M16 x 100, bearing clamp AtiIW2185F 2 Nut, M16 Nyloc, bearing clamp bolt ANIIW3159F 2 Thrust Washer, outer ANICOII7F. 2 Thrust Washer, inner ANICONBF 2 Dust Shield, front wheel bearing B111C0076F 2 Washer, M16x30x2 ANWat71F 2 The M16 clamp bolt set is a direct replacement for the M12 set, and itis recommended that at the time of fitting, the hub Is removed from the bearing and the condition of the hub spigot carefully examined. If any signs of bearing inner race movement on the hub are evident, the hub and bearing should be renewed and assem- bled with the new bolt set Inner thrust: washer Outer thrust washer M16 bolt M16 Nyloc nut Flat washer Hub eh Dust shield Hub carrier The replacement procedure is detailed in Elise Service Notes sub-section CG 4, but also note the following points: @) The M12 bolts are handed - RH thread on RH side, LH thread on LH side. The M16 bolts are not handed, but use a higher torque setting of 210 Nm (previously 77 Nm). b) The assembly configuration is as shown in the illustration, with the bolt head and dust shield on the inside, ang the nut on the outside. Note that the plain washer is fitted between the bolt head and dust shield, ————— Page 21Ly pee Raia Aamo Sac XA10- FRONT ANTI-R( 111601; For competition use, a stiffened tubular front anti-roll bar (14 gauge wall thickness replaces 17 gauge) is available which also provides a 5 hole choice of drop link attachment. The bar is a direct replacement for the standard bar, but must be used in conjunction with the Nylon block type chassis mountings, not the later bonded rubber mounts introduced in March ‘98. For later cars, discard the rubber mountings and order sepa- rately the Nylon mountings and associated fixings. Notes: = The 'top hat’ spacer bush in the Nylon block should be fitted with the flange abutting the chassis. = Lubricate the bar to Nylon block using MoS, grease. = Tighten the wishbone pivot bolt and anti-roll bar drop links to 45 Nm. Lower Wishbone Front Pivot Detail Flanged spacer tube Bonded reinforcement plate Split Nylon block. Wishbone pivot bolt Bonded inserts M5 clamp bolt Lower wishbone Anti-rolll bar drop link- Anti-roll bar end plate Page 22Lotus Service Notes SC XA.11 - OIL COOLER KIT- A111K0037S The oll cooler kit is recommended for use with the 190 VHPD engine, and includes a 9 row cooler ‘Mounted to the front crash structure beneath the radiator duct, into the floor of which are cut air feed holes, with air exhausting from the oil cooler via an aperture in the revised front undershield. The oil cooler feed and return hoses are routed from a new oil filter housing via the RH sill and front wheelarch. Qil Cooler Kit Contents Description Part no. ay Oil Cooler Kit AN1KOO37S— st comprising: Oil Cooler AINIKOOSeF 4 Oil Filter Housing ANIESI46F 90° Connector, oil pressure switch AITIES147F 4 Hose, oil cooler feed AINKOOS5F 4 Hose, oll cooler return ANKOO34F Mounting Bracket, oil cooler ANtKOO32F 4 Duct, oil cooler AIN1KOO39F Undertray, front AINBO400F 1 Convolute Hose Protector A0B2V7779V 300mm. Grommet, cooler hose AQ79U6033F 4 Miscellaneous Fixings Convolute protection Oi filter housing / Cut holes in body ‘A’ post Air infet holes Sill baffle Oil cooler feed hose Hoses clipped to top of wheelarch liner Oil cooler return hose Oi! cooler Oil cooler duct Mounting bracket a Front undertray. Page 23na) Lotus Service Notes Tate ting Procedure 1 crash structure floor 83 mm diameter holes Cooler hose holes in crash structure RH side 3, Replace the oil filter housing on the engine with the new housing which incorporates feed and retum ports for the oil cooler hoses. Transfer the oil fter canister. Fit the new blanking plug into the tapped hole in the top of the housing. Using a thread sealant, screw the new adaptor elbow into the tapped hole on the Underside of the housing, and from the old fter housing, transfer the brown bodied oil pressure switch into the elbow. Note: i) Ifa new VHPD engine is being fitted, tie back the unused black coloured hamess connector (oil pressure gauge transducer). i) I the old oil pressure switch is the later, post Jan.'98 parallel thread type, the earlier type tapered thread switch must be ordered and fitted - A111E6099S. Remove the front clamshell and undertray. Mark up and cut the air inlet holes in the floor of the crash structure as shown in the diagram, and also the hose routing holes in the RH side of the structure. Fit ‘grommets into the hose routing holes. Towing strut fixing holes 30 mm holes for cooler hoses 6.5 mm holes (oil cooler mounting bracket) hg ssh ‘Undertray front fixing = Remove the lower centre three fasteners for the radiator air intake grille, and fit the oil cooler air intake duct to the underside of the crash structure using the two fixings a the bottom of the ‘towing eye strut. Rifit the grile fixings. Apply foam strips to each bottom flange of the duct. Fitthe oil cooler radiator to its mounting channel using the two thin head screws, and position the assembly beneath the crash structure, against the rear end of the intake duct. Mark up and drill two M6 clearance Page 24re) Lotus Service Notes Eee. 5, Cooler hose holes in ‘A’ RH sillA' post top surtace —— 10. holes in each side of the crash structure for the cooler mounting channel fixings, and secure the channel. Mark up and cut the two oil cooler hose routing holes in the front face of the body RHA’ post as shown in the diagram. Remove the coin tray from the front of the driver's door sill. With the aid of an assistant, feed the two hoses through the body sill from front to back, using access via the coin tray aperture and open rear end of the chassis rail. First feed the right angle hose union through the sill baffle aperture before feeding through the straight union on the second hose. st front f 75) ) 125 Use convoluted hose protection at the rear end of both hoses where they exit the sill area, connect the hoses to the unions on the oil filter housing, and tie strap to the adjacent water hose, and/or together as necessary. Fit a grommet onto each hose and locate in the ‘A’ post holes. Feed the hoses through the side of the crash structure, and fit the grommets into the holes. Connect the hoses to the oil cooler and secure the LH hose the the centre rib on the crash structure using a'P' clip, Fit the front topshell and secure the two hoses around the top of the wheelarch liner using 'P' clips before fitting the liner. Disable the ignition and crank the engine to fill the oil cooler and pipes before starting the engine, Check the hose connections for leaks before fitting the new front undertray with the swaged aperture pointing downwards. Page 25,ce) Lotus Service Notes Section XA XA.12 - BATTERY ISOLATOR SWITCH KITS This dual pole flick switch is mounted in the cabin and operates the ignition circuit directly, and via a relay in the battery compartment, all other battery services. An alternator dump resistor is incorporated to protect the altemator from damage. In addition, external operation of the switch is provided for bya Bowden cable link from a pull handle located in the topshell near the windscreen base. Contents of Kit Battery Isolator Switch Kit (prior intro. of revised harness)" AI11MO128S— 1 Battery Isolator Switch Kit (from intro. of revised harness) AN1MO129S.—t comprising: ‘Switch Box Assembly (prior revised harness) ANNIMOIZ6S 1 ‘Switch Box Assembly (revised hamess) ANIMO125S Master Switching Relay AItIM6087S 1 Bowden Cable AMTiM6088S 1 Battery Positive Link Cable A111M0109S Miscellaneous Parts : * New harness introduced at VIN: W 1941. Plus; 1920, 1926, 1937, 1938. Less; 1965, 2002. ‘Component Siting ‘Switch Box Assembly: Position the switch box on the car centreline (or offset if piumbed-in fire extin- uisher system is fitted) beneath the dash, mark up the two pre-drilled holes in the box against the dash, and drill the dash to secure the box using two self tapping screws AO7SWS014Z. Route the harness alongside the main harness and through the bulkhead grommet to the front of the battery well Route harness through grommet Operating switch boxae) Lotus Service Notes State eaey 2. Master Switch Relay: Using one existing Puisert in the battery well, mark up and drill a second fixing hole mm diameter and fit an M6 Pulsert AO73W6156F. Secure the relay using two M6 screws, with a ‘Pclip located under one of the fixings to carry the alternator dump resistor. 3. Drill the topshell 13 mm diameter in the position shown to locate the Bowden pull cable. Fit the cable handle and route the cable through the front compartment and plastic bulkhead cover to the operating switch housing. Fit the inner cable through the hole in the switch lever and fix the outer cable adjuster in the casing. Secure the cable to the dash underside with a ‘P’ clip as shown, Bowden cable handle Alternator dump resistor Electrical Connections 1. 2, Disconnect battery (negative cable first). Replace existing mm eyelets on battery positive cables with 6mm eyelets using crimp and solder tech- niques. Fit new masterswiteh (relay) into the battery well as shown in the illustration, and attach the positive cables to one of the switch terminals, Fit the new battery positive link cable (A111MO109F) from the other masterswitch terminal to the battery. Prior to revised harness: ~ Unwrap the main hamess at an area 175 mm from the fusebox to locate splice 'D' where 4 white cables are joined. Identity the thin white cable to the rear of the splice. Cut this cable 100 mm from the splice, and Page 27PR CEA ey Sale cN to one of the ends, use splice crimp, solder and heatshrink, to connect the new green 1.0 mm wire leading to the new fuse holder to be attached to the side of the main ‘usebox and equipped with a 10A fuse. - Insert into the other cavity of the new fuseholder, the terminated green wire from the new switchbox. ~ To the remaining end of the cut white cable, splice crimp, solder and heatshrink the unterminated green wire from the new switchbox. - Release the main fusebox fixings, remove fuse 7, and extract the green cable from cavity 7B. Cut off the terminal from this cable and use splice crimp, solder and heatshrink to connect with the unterminated green cable from the new switchbox. - Insert the terminated green wire from the new switchbox into the vacated fusebox cavity 7B. - Replace fuse 7 (10A) and rafit the fusebox. Operating switch Switchbox Bowden cable Green: to new fuseholder Unterminated black: to alternator dump resistor harness Black; to battery negative Black: to cavity 'B' in 2-way master switch connector Unterminated green: spliced to main harness white Green: to new fuseholder With revised Unterminated black: to alternater dump harness resistor Black; to battery negative Unterminated green: spliced to green cable extracted from fusebox cavity 7B Black: to cavity 'B' in 2-way master switch relay connector e Page 28i WOES Section XA 6. Use splice crimp, solder and heatshrink to connect the new red (2.0 mm) wire to the altemator dump resistor, and connect the other end to the master switch relay terminal with the other re-terminated battery positive cables. 7. _ Use splice crimp, solder and heatshrink to connect the unterminated black wire from the operating switch to the remaining wire on the alternator dump resistor. Locate the resistor in its 'P' clip by the side of the master switch relay. 8, tthe master switch relay smalltwo way connector, use the new red (0.75 mm) wire to connect cavity ‘A to the master switch terminal with the battery positive link (A111MO109F) attached. 9. Insert the terminated black cable from the operating switch into cavity 'B' of the two way connector on the master switch relay. 10. Connect the ring terminated black cable from the operating switch to the battery negative terminal 11. Reconnect battery. 12, If the car is to be used in competition and the passive immobilisation system is required to be disabled, extract the two purple and white cables from the Lucas 5AS module harness connector, and tape back. “NOTE* When the ignition is turned off, ensure also that the operating switch is turned off, as otherwise a battery drain will occur via the energised master switch relay. Circuit diagram - Prior to revised harness

eves | | tot sur <}-—v 55g —————— Page 30i Sa eed Saree EMOVEABLE STEERING WI 11110026) The motorsport removeable steering wheel is a direct replacement for the standard wheel, and allows for Quick detachment of the wheel for improved cabin access, and can provide an increased measure of theft Protection. The Momo three spoke wheel is the same 320mm (12% in) diameter as the standard wheel, and is {rimmed in red leather, with contrasting leather inserts in the thumb areas. A removeable key tarrel provides the option to lock the wheel to the column, and positional variations of the three wheel to hub drive pins, ensures that wheels cannot be interchanged between similarly equipped cars. Eitting instructions 1. Remove the standard steering wheel: ~ Pull off the centre trim pad with horn button and disconnect the two horn leads. ~ Remove the column nut and match mark the hub to the column to aid alignment on re-assembly. ~ Use a suitable steering wheel puller tool to locate behind the steering wheel boss and bear against the fend of the column, CAUTION: If excessive force is applied to either the wheel or column without an appropriate puller, the telescoping mechanism of the outer column may be activated, necessitating column. replacement. 2. Dismantle the standard wheel and retain the splined hub, and the horn slip ring carrier. 3. Assemble the new wheel assembly: + Fit the hom contact adaptor into the locking ring with the alignment pip and notch engaged. - Secure the steering wheel spacer ring to the locking ring with six countersunk screws, using a suitable thread lock. + Fit the steering wheel to the spacer ring with six countersunk screws, using a suitable thread lock. ~ Connect the two leads to the new horn push - red to centre, black to side, and press the button assembly Into position, - Fit the hub spacer ring to the splined hub using four caphead screws and suitable threadiock, with the eyelet of the new horn extension lead beneath one of the screw heads. - Fit the hom slip ring carrier to the splined hub, feeding the two wires through the hub and spacer ring. Ensure that when the splined hub is fitted to the column, the turn indicator cancelling vane is on the left hand side. ~ Check that the column bearing preload spring is fitted onto the column before fitting the splined hub with the match marks aligned. Fit the column nut and tighten to 25 Nm. Connect the hom lead spade connectors to the spigot hub and insulate with the sleeves provided. Fit the spigot hub to the hub spacer ring with the notch on the hub periphery aligned with the ‘TOP’ mark on the reverse side of the splined hub and secure with the six countersunk screws, using a sultable thread lock. Fit the steering whee! onto the spigot hub and check the operation of the key barrel lock, horn button, and indicator cancelling mechanism, Illustration overleaf Page 31Hom slip ‘M6 x20 capscrew ring carrier ‘A082W7041F M6 x 16 screw A918W7120F Hom earth Steering wheel Spigot hub _ extension Alignment Splined hub Hub spacer Key lock barrel Horn contact Locking adaptor ring Horn push button Page 32i Lotus Service Notes Saree 4= STAGE 2 (135 BHP) ENGII TUNE UP KIT-A/B111E6215S This kit comprises a reworked cylinder head assembly and cast alloy intake manifold and plenum. It is designed to be used in conjunction with the competition silencer (A111S0037S), and for track use, with the cata- lyst replacement pipe (A111S0048S). Cars fitted with an aluminium boot bulkhead will also require this item changing fora reprofiled version supplied inthe kt. A modified engine cover ld in composite material is available to clear the new intake plenum, butit is possible to trim/modify the existing aluminium lid to fit ‘A running change made to the cam belt tensioner mechanism on the Rover K16 engine requires that cylinder heads with different belt tensioner machining details are used. On engines with serial numbers prior to 183093, kit A111E6215S should be used, with later engines using B111E6215S, Contents of Stage 2 Kit Cylinder Head Assembly comprising: Cylinder head Cam cover Cam cover bolts Tappets Valve spring cap Valve stem seal Valve spring Modified inet valve Modified exhaust valve Valve collets Inlet camshaft Exhaust camshaft Camshaft oil seal Cam cover gasket Cylinder head gasket Blanking plateivac. spigot Inlet manifold stua Exhaust manifold stud Inlet manifold gasket Exhaust manifold gasket Upperlower manifold gasket Screw Manifold support strut Screw Screw ‘Spark plug Spark plug cover (green) Modified inlet manifold upper Inlet manifold lower ‘Screw, upper to lower manifold Adaptor, AIT sensor ‘Water outlet elbow gasket Fuel return pipe Boot bulkhead Oty 1 1 1 16 16 16 16 16 8 8 2 Aeneas ese sors canssansag 1. Check parts supplied against above list. 2. Refer to Elise Service Notes manual section EE, and remove the cylinder head. If the caris fitted with an aluminium boot bulkhead, remove the bulkhead, 3. Remove from the old cylinder head the plastic inlet manifold assembly, 4, From the plastic inlet manifold assembly, remove the following components for re-use: ——— 1999 /01 Page 33,5 6 7. 8 9 10 1" 12. 13 14 15. 16 17. Z7~ “3 Lotus Service Notes eee Air inlet temperature sensor, - Fuel rail and injectors, «Idle air control stepper motor; - Throttle body and breather pipes. Remove from the old cylinder head the following components for re-use: - Cam belt tensioner spring pedastal bolt; = Rotor arm and anti-flash shield; ~ Distributor cap and HT leads, - Water outlet elbow, ‘Assemble the new inlet manifold -Fitthe new upper inlet manifold (plenum) to the new lower manifold with gasket and screws; - Fitthe throttle body assembly to the new plenum: ~ Fit the air inlet temperature sensor with its new adaptor into no.4 branch of the new lower manifold; - Fit the new blanking/vac. spigot plate with gasket to the end of the new intake plenum; - Fitthe fuel rail assemby and injectors into the new lower inlet manifold; ~ Fit the new fuel return pipe to the fuel rail Assemble the new cylinder head; - Fit the cam belt top cover, - Fit the camshaft pulleys; - Fit the two new inlet manifold studs into the top two fixing holes in the head: - Fit the five new exhaust manifold studs; -Fit the distributor cap and leads; - Fit the timing pedastal bolt, Fit the water outlet elbow and gasket - Fit the new inlet manifod assembly, Fit the new cylinder heac assembly as detailed in service notes section EE, paying attention to the crank- shaft and cam positioning to avoid piston/valve foul Fit the new manifold support strut to the manifold and cylinder block using the new bolts supplied. Connect the fuel pressure regulator valve sensing hose and MAP hose to the right hand end of the intake plenum via the two spigo's, or single spigot and 'T"-piece Fit the exhaust manifold ‘With camshaft cover removed, pour oil over the camshafts and valve gear to ensure adequate lubrication on start up. Fit cam cover and new spark plug cover. If applicable, fit the new aluminium boot bulkhead. Feitle and/or modify the engine cover lid as necessary to provide sufficient clearance to new intake plenum, Fill the engine with a good quality mineral (not synthetic) oil meeting the viscosity requirements of the standard engine, (see Cwner's Handbook or Service Notes Section OG), and change the oil and filter after the running in period of 1,000 miles, Part or fully synthetic oil may be used to advantage after runniing-in, with the same viscosity requirement Note that for the hydraulic tappets to prime, the engine may require cranking for an extended period. For normal road use, the standard maintenance schedule may be used, with oil and filter changes at 8,000 mile intervals. For cars used on circuit ‘track days’, it is recommended to reduce the change interval to 3,000 miles, and for full race use, change every two meetings. Page 34 11 1999 /01a UST Ade eee} State IAA The Yokohama A038-R tyre has been jointly developed by Lotus and Yekohama specifically for the Lotus Elise, and whilst the specification is optimised for track use, the tyre is road legal in the U.K. and Europe. ‘The {yre offers a high level of grip in both dry and wet track conditions combined with good braking performance ‘The water clearing abilty of the tyre is limited in standing water, such that appropriate allowances should be made in these conditions. For competition use, the eligibility of the tyre should first be checked with the appropriate organising authority. Note that the tyre tread pattern is directional, with the correct rotation marked by an arrow on the sidewall The potential chassis loadings provided by this tyre require that it be used only in conjunction with the Sport road spring and damper set, lowered ride height, specific suspension geometry (with increased negative camber), uprated front anti-roll bar and Uniball rear toe link kit. The tyres should be mounted on factory approved Elise race’ wheels (6J front, 8J rear) in order to provide good tread stability for ultimate performances Tyres Tyre designation Yokohama A038-R Size front 195/50 R15 82V (K-5243) ~rear 225/45 R16 BOW (K-5244) Pressure (cold) - front 1.6 bar (23 Ib/in?) ~rear 1.7 bar (25 Ib/in’) ‘Suspension Geometry Refer to sub-section XA.8 to set the chassis to the lowered ride height of 100/110mm frontrear, and to set the steering rack height and rear bump steer shimming. The following suspension geometry setting is recom. mended for dry circuit use tem Specticat Tolerance Max, difference side/side Front Camber: -1.8° 0.2° Front Caster +38 az Front Toe: 0.5mm toe out overall + 0.2mm, - 0 Rear Camber*: 27° + 0.2", -0.2° 2° Rear Tos 2.5mm toe in each side + 0.2mm, -0 “Itmay be necessary to machine the top ball joint plinth in order to attain sufficient negative camber. 2000 / 02 Page 35ma) SAL) irate, 16 - 340R 34 HI 17S, LHD: A: Lstse9 ‘The purpose of the 340 ps/tonne kits to optimise the performance potential for use on closed race tracks. ‘Amajor part of the package involves the removal of components to save weight, with the full procedure below resulting in a dry weight of 871 kg. With a power output of 195 ps, a powerweight ratio of 340 ps/tonne is achieved. The RHD kit includes an oil cooler fitting kit, which is factory fitted on LHD cars. Kit Contents Engine: 190 bhp ECM (surcharge on old unit) 101° Inlet cam pulley Breather hose kit 82°C thermostat Track exhaust muffler (stainless ste!) RHD kits only: Oil cooler kit Grommets for airbox, backplate and oil catch tank Blanks for inlet manifold IAC ports Clutch: Uprated (higher clamp) clutch cover Uprated (material) friction plate ‘Standard release bearing Chassis: Road spring set Pagid Motorsport brake pad set Castrol racing brake fluid Goodridge braided brake hose Body: Rear diffuser panel and brackets Carbon fibre headiamp banks Polycarbonate windscreen Electrical Lightweight race battery Rear racelight conversion kit Immobiliser bridging link Sidelight switch connector bridging link Hazard switch aperture grommet Column switch aperture blanks Alloy cover for bulkhead electrics box Miscellaneous: Carbon fibre seat Removable 305mm steering wheel kit Elise gear lever surround Driver only roll over bar (RHD or LHD) 5 point driver's harness kit Allloy fuel tank Camber shim plates Delete air intake resonator valve: Remove the air intake resonator valve and control mechanism including the vacuum reservoir and two solenoid valves. Re-plumb the MAP sensor. Discard the secondary air cleaner at the airbox inlet, and connect the intake trunking directly to the airbox, with the primary air cleaner at the front end of the trunking, which can be sited close to, or connected to the air intake duct on the LH flank. Take care ‘when washing, to avoid directing jet wash equipment into the intake duct - blank off if necessary. Delete breather rail: Remove the steel breather rail from the inlet tracts. Remove breather hose from cam cover to rail. Fit alloy blanking plugs to inlet tract spigots. Delete charcoal canister: Remove the charcoal canister and plumbing, Vent the fuel tank breather pipe from the roll-over valve to atmosphere. Pagess — a1a Lotus Service Notes Sree. Delete IAC valve: Remove the idle air control valve, mounting bracket and plumbing. Fit blanking plugs to the inlet tract spigots on manifold underside. Fit blanking grommet to backplate Et breather hose kit: Remove the screenwash bottle and battery clamp bracket from the front chassis welt Gut the top, bottle mounting portion, of the bracket from the lower, battery clamp, section, and paint protect the Cat Surface. Rivet the bottle mounting bracket tothe LH side of the engine bulkhead, and fit the washer bottle Wah motor aperture blanking grommet, to the bracket to act as oil catch tank. Remove the breather hose Petween cam cover and airbox, and fitthe grommet to the airbox hole. Use the breather hose kitto connect the {wo cam cover breather spigats tothe catch tank, cutting a 13 mm hole in the top surface of the bottle to admit the breather hose, and a similar hole in the bottle filer cap to allow breathing. Fil race exhaust system: Remove the catalytic converter and standard muffler, and replace with the track muffler. Fitlower temp. thermostat: Replace the standard 88°C thermostat with the 82°C thermostat, Exchange ECM: Replace the standard ECM with the reprogrammed unit, and return old unit to Lotus. RHD only: Fit oil cooler kit: See separate instruction sheet LSL3AA 4 Inlet Cam tr Slandard engine inlet cam timing is 105° ATDC maximum opening point. The modified pulley supplied in the kit allows the inlet cam timing to be advanced by 4° to 101° MOP. 1. Remove the timing belt top cover. 2. Turn the engine to align the timing mark on the crankshaft front pulley wit the ‘safe’ position 45° ATDC mark (12 O'clock) on the timing belt lower cover. Check that the camshaft pulley timing marks are aligned towards each other; if not, turn a further 360° 3. Slacken the belt tensioner clamp bolt, and remove tension from the cam belt. 4. Use special tool T000T1280 to hold the inet camshaft pulley and release the retaining bolt, Withdraw the pulley from the camshaft and timing belt. 5. _Fitthe new pulley to the camshaft with the 'T’ mark just above the timing mark on the exhaust camshaft pulley and the dowel engaged in the pulley slot. Use special tool TO00T1280 to hold the inlet camshaft pulley and tighten the M10 retaining bolt to 65 Nm & TU the inlet camshaft to align the inlet pulley mark wih the exhaust puley EXHAUST’ mark, and sip {he belt onto the pulleys ensuring that the drive side of the belt i tight and the crankshaft pulley is sti Positioned at the 90° ATDC mark 7 Using a 6mm hex. key, rotate the tensioner counterclockwise and align the centre of the indent on the {ensioner pointer with the index wire ensuring that the pointer approaches the index wire from above. If the pointer passes the wire, release the tension completely and repeat the procedure, 8. Ensuring that the pointer does not move, tighten the tensioner bolt to 25 Nm. 8. Using the crankshaft pulley bolt, slowly turn the crankshaft 2 tums clockwise to check there is no valve piston contact, and re-align the timing marks without having to back up’. Check that the tensioner pointer 's stil correctly aligned with the index wire. If not, slacken the tensioner bolt unti itis just possible to ‘move the lever clockwise, and position the pointer just above the index wire. Continue with operation (7) 10. Refit the belt guards. ‘Clutch Kit ‘The clutch kit s a direct replacement for the standard components. See Service Notes section QF. Rear difuserpanel: Remove the rear diffuser panel, and replace withthe new (standard Elise) panel using new mounting struts which attach to pre-drilled holes in the subframe top rear flange. Carben fibre headlamp banking panels: Remove the headlamp and turn indicator lamps, and cut the lampra) ESA ekce} irae housings from the topshell with a windscreen removal pneumatic knife. Fit the headlamp bianking panels to the topshell using elastomeric adhesive. Polycarbonate windscreen: Remove the windscreen, and replace with the lightweight polycarbonate version. Refer to Service Notes sub-section BN. 13. Remove: = Complete wiper mechanism, including washer components. = Rear shroud panel (mid spoiler) complete with rear fog lamp, reverse lamp, hamesses, grilles and brack- ets = Allfour mudguards and mounting brackets. Fit camber shim plates supplied to compensate for mounting bracket thickness. - Engine bay rear wall = Driving lamps and mounting brackets, - Horn. - Front licence plate mounting and brackets. - Front air intake grille and towing eye. = Tyreweld canister and mounting clip. - Rear window. - Exterior mirrors and alloy spacers/plinths. Fit blanking grommets in topshell holes. = Side repeater lamp plinths. Bond repeater lamps to body with elastomeric adhesive. ~ Right hand side engine bay air intake duct. Battery. Replace the standard battery with the lightweight race battery and mounting bracket. Race light conversion: Change the two outermost bulbs in the CHMSL to 3W to become the racelight, acti- vated with the ignition. The centre two bulbs remain as stop lamps. Fit the link lead suppied in the kit, as directed by the specific instructions supplied (LSL380). Remove: + Alarm controller, siren and bracket, microwave sensor, immobiliser and alarm hamess. Plug bridging link into immobiliser connector. - Footwell divider alloy panel = Cockpit divide switches, mounting panel and strut. Plug bridging link into sidetamp switch connector. - Gear lever/handbrake shroud, with trickle charger socket. Fit standard Elise gear lever shroud - Auxiliary power sockets, mounting panel and hamess. - Hazard switch and fit grommet. = Column switches and fit alloy blanks using elastomeric adhesive. - Rear indicator and tail lamp assemblies, inc. mounting brackets and hamesses. - Licence piate lamps and harness. - Engine cover lid alarm switch and harness, - Top shell hamess. - Relays; main, aux., dip, horn, heated screen; and relay cover. = Fuses; 2,4,5,6,9,10,14,16,17, 18,20,21,22 and fuse cover. - Passenger footrest. = Luggage net - Floor mats. = Interior mirror. - __ Fixthe alloy blanking panel to the aperture in the rear bulkhead electronics cover using double sided tape or rivets. Miscellaneous Seats; Remove the passenger seat and mounting frame. Remove the driver's seat but retan the runners. Driver's 5th point seat harness kit: Remove the latch from the seat harness lap strap by inserting a stiff wire into the latch hole. By similar technique, ft the new rotary release latch to the lap strap. Fit the grommet onto the new crutch strap, and thread the anchor bar through the crutch strap loop. Feed the strap through the seat frame cross brace aperture and the slot in the new carbon fibre driver's seat, and ft the gromrret into the frame aperture. Fit the new seat to the runners with the crutch strap anchor bar secured beneath the cross brace by the seat front fixings, Roll over bar, Remove the double hoop roll-over bar, and replace with the driver only, RAC approved, (RHD or —_—_—$—$—————WuMm...___ Page 3816) Lotus Service Notes ira rey LHD) bar. This will requite a clearance slot to be made in the engine lid and body aperture gutter. A template (LSL401) for the engine lid slot is provided with the bar to allow an initial fit to be made, with intial dimensions for the body aperture measureable from this. The spoiler mounting plate wil also require a small clearances groove to be made to allow the backstay to be connected, The body on each car will require individual fetting, ut with care, no painting should be required. Note that with this bar fitted, a passenger seat MUST NOT be fitted. Removable steering wheel; Fit the removable steering wheel kit as detailed in sub-section XA.14, Delete handbrake: ‘Remove handbrake lever, mounting bracket and cables, Remove the lever and spring from each rear brake caliper. Alley fuel tank: Remove the steel fuel tank and replace with race alloy tank using original pump and fittings (refer to section LH). Berd the float arm of the gauge sender to clear the side panel of the new tank. Heater duct: Remove the heater offtake duct from the radiator, the heater trunking, and the duct onto the footwell vents. The uprated brake pads, racing brake fluid and braided brake hoses are all direct replacements for the stand- ard components, but note ‘hat the rear hoses do not use the P’ clip on the lower wishbone, but are tie strapped in two positions to the toesink. Road springs: If the full lightening programme has been carried out, the new road springs should be fitted in order to maintain spring compression at full droop. Spring rate is the same as standard 340R, With the car loaded with driver (or 7Skg) and a half tank of fuel (plus all fluids), adjust the spring platforms to set the ride height to 100 mm front, and 110 mm rear. At only this ride height, set the suspension geometry to that specified in service notes 340R.C and 340R.D for either road use, or dry track use dependent on customer preference. LHD; 24.0 hrs RHD (inc. oil cooler fitmen:); 27.0 hrs, 2000 / 02 ge 391) ECR adc ay Sree eeN tsis88 All LED 340Rs were factory built with oll coolers, The following procedure outlines oil cooler fitment to a RHD 340R, recommended for use on race tracks or in conjunction with the 340ps/tonne kit KitContents: Oil Cooler AS40ES025F 1 Gil Fiter Housing AMIESI46F 1 Gasket, oil fiter housing ANIE6101F il Fiter AIME6O38S 90° Connector, oll pressure switch ATTIEG1A47F_ 4 Oil Pressure Switch AMI1E60995 1 Hose, oil cooler feed AB40E0036F 1 Hose, oil cooler return ‘AGAOE6020F 1 Grommet, cooler hose BINIGeOIZF 4 Pillar Nut, M6, oil cooler mounting A340E0034F 4 Setscrew, M6x12, oll cooler fix A000ZTOASF 8 Washer, fiat, M6 AOTSWA013F 8 ‘P* Clip, open, cooler hose fix AOTSWE229F 8 Pop Rivet, ‘P' clip AO7SWGOB7F 8 Fitting Procedure 1. Remove the body topshell (see sub-section 340R.B) 2. Replace the oil fier housing on the engine with the new housing which incorporates feed and retum ports for the oil cooler hoses. Fit the new oil fitter. Using a thread sealant, screw the new adaptor elbow into the tapped hole on the underside of the housing, and fit the new brown bodied oil pressure switch into the elbow {note that the new switch is taper thread, old switch parallel thread), 3. Cut a pair of 32mm diameter holes for the cooler hoses in the right hand outer wall of the radiator duct, Just ahead of the engine coolant hose aperture, and another corresponding pair of holes in the rad. duct inner wall 4. Position the oil cooler in the intake air duct, approx. 50 mm behind the towing strut. Mark up the fixing holes in the floor of the duct, and dil Mé clearance holes. Mount the cooler using the M6 fixing screws and washers, with the pillar nuts between the duct floor and cooler. 5. Connect the cooler hoses to the oil fter housing, with the 45° return hose union fitted to the housing right hhand port, and the swept 90° union on the feed hose connected to the left hand port. Take care to route the feed hose, with its heat protective sleeving, away from the exhaust downpipe, and secure to the water rail at the front of the engine bay. Route both hoses against the bulkhead, outboard of the fuel filer hose, ‘and through the engine bay RH air intake aperture (on some early cars, it may be necessary to cut an aperture in the side closing panel). Ensure that both hoses are fitted with convolute protective sleeving in vulnerable areas, especially through the air intake aperture. 6. Route the hoses against the upper part of the cockpit closing panel, beneath the coaming, and secure with 'P lips, positioning the clips to allow access to the topshell fixing studs. Continue routing against the windscreen buttress and RH top rear comer of the radiator duct, clipping as required. Take care not to inhibit topshell fitment or headlamp access. Feed the hoses through the air duct holes, and fit the grommets. Connect to the oil cooler, using two spanners to prevent the cooler unions being twisted. 7. Disable the ignition low tension and crank the engine to fil the oll cooler and hoses before starting the engine. Top up oil level if required. Run engine and check for leaks before refitting the topshell Recommended Fitting Time 6 hrs (including topshell removelrefit) Page 40,12) Lotus Service Notes Srl eAe 2000 / 02 Page 41ra) CES A es ly Sire olga 18 - RAI Lsisee ‘The Goodridge steel braided brake hose set is a direct replacement for the standard hoses, with the following exception: - The rear hoses do not use the standard places to the rear toe-link, clip on the lower wishbone, but should be tie strapped in two XA19 - STH Lsis93 Remove the latch from the seat harness lap strap by inserting a stiff wire into the latch hole. By similar technique, fit the new rotary release latch to the lap strap. Fit the grommet onto the new crutch strap, and thread the anchor bar through the crutch strap loop. Feed the strap through the seat frame cross brace aperture and the slot in the driver's seat, and fit the grommet into the frame aperture. Secure the crutch strap anchor bar beneath the seat frame cross brace by the seat front fixing studs.ie tus Service Notes State Lsts90 The racelight conversion kit provides for the Centre High Mounted Stop Lamp (CHMSL) to be used for both a brake lamp, and also a racel ght activated with ignition, 1 Disconnect and remove the CHMSL from the topshell and cut the lower (+ve feed) copper track in two Places as shown, to separate the function of the two outermost bulbs from the inner pair 2. Replace the two outermost bulos with 3W items, 3. _ Solder the ends of the two green cables on the new hamess to the outer bulb +ve tracks 4. _ Refit CHMSL to topshell, connect conversion harness to lamp, and secure to topshell and plug in to main hamess 4-way connector. 5. _ Fit bridging link into main harness sidelamp ewitch connector. Lamp connector plug Plug into main harness N ic) Solder bare ends of cables Cut copper track on conversion harness Page 43 2000 / 02Lotus Service Notes Sao XA21- TONNEAU COVER (RHD - A340V6000S: LHD - A340V60228) This tonneau cover is manufactured from an Acrylic material with a polyurethane coating on the inside, and not from Haartz material as stated in some sales literature, Stowage itis important that the tonneau cover is not kept in the storage bag for long periods when wet, as this will affect both the aesthetics and the polyurethane coating Rear Screen If the car is for track use, the rear screen may be removed. For road use, the screen should be retained (legal requirement) but a procedure is included to modify the screen mounting to allow for easy fitment of the tonneau cover. Fitting Procedure 1. Remove the passenger seat, slide the driver's seat fully forwards, and remove the cover from the rear bulkhead electronics box. 2. Remove the rearscreen. For race use, use grommets to blank off the screen fixing holes in the bukhead, 3. If the screen is to be retained; ~ Bond an MS x 12 big head stud (A082W5128F) into the two screen fixing holes in the bulkhead electronics box from the inside. ~ Inthe screen mounting bracket, drill a (mm diameter hole 9mm from each of the two fixing stud Positions, towards the rear edge of the bracket. ~ Cut the studs from the bracket, and grind flush. Paint the underside of the bracket black, ~ To fitthe screen, locate the screen bracket onto the two studs, and secure with the plastic wing nuts (anitwat4sr). Wing nut ANN1W3146F Drill new holes Big head stud A082W5128Fa Sa ec) See 4. Push the tonneau half round dash section into place below the windscreen and above dash. Hold in place whilst marking each ‘A’ post for the socket position. Remove tonneau, and dri a suitable hole in each Screen pillar for the self tapping press stud socket. Fit the two sockets, 5. _ Fitthe tonneau to the screen pillars, and pull tight into the roll hoop centre gap. Mark topshell deck with Positions of the two sockets, and drill and rivet into place with black rivets, 6. Pull the cover around the rest of the cockpit, and mark the postions of the remaining sockets as shown in the diagram, Take care when driling the topshell to limit penetration so as not to damage any parts below (e.g. hamesses or hoses). Rivet the sockets to the body, and fit the tonneau, routing the drain tubes at the front beneath the instrument rail and into the passenger footwell, where excess water can drain away. By Lunzipping the driver's side of the tonneau, and stowing the rolled section behind the driver's seat, the car an be driven with some interior protection. Note that the rear screen should be in place when driving in this configuration, ‘'A' post socket Topshell socket Drain tubes Driver's zip Velcro strap 2000 / 02 Page 45ea Lsise4 The 190 BHP exchange engine ECM is designed for track use only, and includes the following features: = Modified fuelling and ignition maps; = Open loop fuelling; - Rpm limit raised from 7,800 to 8000 rpm; - Rad. fan switching point lowered from 104°C to 92°C. The ECM is calibrated to optimise performance with the following performance parts fitted as a package: : Deletion of intake resonator valve, A340E0011S _ 101” inlet camshaft pulley; LOTACOS06S Stainless steel catalytic converter replacement pipe; ‘A340X6013S Breather kit (inc. breather rail blanking plugs & idle stub blanks); ‘A3A0E6011S 1 litre breather catch tank; ‘A340K6007S 82°C thermostat, A340E0035S Oil cooler kit (RHD); Exchange ECM (0.8 hr) Replace the standard ECM with the 190 BHP version, and return the old unit to Lotus. A surcharge will apply until the old unit is received. i tor Valve | Remove the air intake resonator valve and control mechanism including the vacuum reservoir and two solenoid valves. Re-plumb the MAP sensor. Discard the secondary air cleaner at the airbox inlet, and connect the intake trunking directly to the airbox, withthe primary air cleaner atthe front end of the trunking, which can be sited close to, or connected to the air intake duct on the LH flank. Take care when washing, to avoid directing jet wash equipment into the intake duct - blank off if necessary 101° Inlet Camshaft Pulley (2.5 hrs) The standard engine inlet cam timing is 105° ATDC maximum opening point. The modified pulley allows the inlet cam timing to be advanced by 4° to 101° MOP. 1. Remove the timing belt too cover. 2. Turn the engine to align the timing mark on the crankshaft front pulley with the ‘safe’ position 45° ATDC. mark (12 O'clock) on the timing belt lower cover. Check that the camshaft pulley timing marks are aligned towards each other; if not, turn a further 360°. 3. Slacken the belt tensioner clamp bolt, and remove tension from the cam belt. 4, _ Use special too! T000T1280 to hold the inlet camshaft pulley and release the retaining bolt. Withdraw the pulley from the camshaft end timing belt. 5. Fit the new pulley to the cemshaft with the 'T’ mark just above the timing mark on the exhaust camshaft Pulley and the dowel engaged in the pulley slot. Use special tool TO00T1280 to hold the inlet camshaft pulley and tighten the M10 retaining bolt to 65 Nm 8. Turn the inlet camshaft to align the inlet pulley ‘T' mark with the exhaust pulley 'EXHAUST' mark, and slip the belt onto the pulleys ensuring that the drive side of the belt is tight and the crankshaft pulley is still Positioned at the 90° ATDG mark. 7. Using a 6mm hex. key, rotate the tensioner counterclockwise and align the centre of the indent on the tensioner pointer with the index wire ensuring that the pointer approaches the index wire from above. If the pointer passes the wire, release the tension completely and repeat the procedure, 8, Ensuring that the pointer does not move, tighten the tensioner bolt to 25 Nm. ee P. rage 46) ere WoC rae e 9. Using the crankshaft pulley bolt, slowly turn the crankshaft 2 turns clockwise to check there is no valve Piston contact, and re-align the timing marks without having to ‘back up. Check that the tensioner pointer is stil correctly aligned with the index wire. If not, slacken the tensioner bolt unti itis just possible to move the lever clockwise, and position the pointer just above the index wire. Continue with operation (7), 10. Refit the belt guards. mi 4 Remove the catalytic converter and replace with the cat. replacement pipe. i hi) Fitthe breather catch tank to the LH side of the engine bulkhead. Remove the breather hose between the cam cover and airbox and fit the grommet to the airbox hole. Remove the breather hose from the cam cover {o breather rail, Use the breather hose kit to connect the two cam cover breather spigots to the catch tank. Leave the other breather catch tank vent pipe free (or fit a Pipercross vent filter). Remove the steel breather rail from the inlet tracts, and fit the alloy blanking plugs to the inlet tract spigots, lete Charcoal 1 (0.2 hn Remove the charcoal canister and plumbing. Vent the fuel tank breather pipe from the roll-over valve to atmosphere. Li erature Replace the standard 88°C thermostat with the 82°C item, BHD Only - Oil Cooler Kit (5 hrs) Note that all LHD cars were factory built with oll coolers. For RHD oil cooler fitting procedure, see XA.17 or LSL388. ional: (Not recommended for 1 ete U hn Remove the idle air control valve, mounting bracket and plumbing. Fit the blanking plugs to the inlet tract spigots on manifold underside. Fit blanking grommet to backplate. Saves 667g, On road based cars, for further performance enhancement between 5,000 and 6,500rpm, and with a weight saving of over 4 kg, the Titanium muffler A340M6011S may be fitted with the catalytic converter, and will meet road noise regulations as well as RAC MSA Section ‘A’ noise regulations. On track based cars, for further performance enhancement between 5,000 and 6,500rpm, and with a weight saving of over 4 kg, the ‘Track’ exhaust muffler A340S6008S may be fitted, which incorporates a cat. replacement pipe. This part complies with RAC MSA Section ‘A’ noise regulations. 1OT Reaulation If the car is required to meet the U.K. MOT regulations, the standard engine breather system must be retained, together with the charcoal canister, and the Motorsport catalytic converter A340S6010S. Deletion of the standard breather system for track use, allows increased mid-range spark advance to be applied. If the standard breather system is retained for road use, it is recommended to use 97 RON Super Unleaded fuel in order to provide a higher resistance to detonation when using the track specification spark advance curve If the idle air control valve has been removed, check that the idle speed is within tolerance, as a low idle speed may cause excessive HC emissions. 2000 / 02 Page 47Saree ste The Tach Timer is produced by Stack specifically for the 340R, and consists of a replacement tachometer with an LCD panel to display the available features which include: Multi-level shift light; Lap times (incl. memory and spilt); ‘Acceleration times; Last comer and straight line speeds ‘Afull instruction booklet is supplied with the kit. Eitting Instructions Remove the standard tachometer and substitute the Tach Timer Level 1 instrument. Connect to existing hamess plug, Remove the steering column lower cowl, and cut a 7mm hole in the RH side, and a 12mmbhole in the LH ‘side to mount the driver push button and rotary switch. Cut a small 4mm wide slot into the lower cowl from the top mating face on both sides, in order to allow routing of the sensor cable From the access hole in the underside of the fascia between the steering column and centre divide, withdraw the harness spur with the black 12 terminal square block connector. Plug in the new switch and lap sensor hamess, and feed through the dash hole into the column shroud area, Mount the push button and rotary switch to the column shroud and connect the hamess, Fit the shroud and route the sensor cable out of the appropriate slot Fit harness clips A100W6353F beneath the instrument rail as shown in the diagram, with 4 under the Passenger side, and 2 under the driver's side. Also fit two along the dash top towards the passenger side A’ post. Fit one tie wrap A082M6556F hamess clip, to each ‘A’ post vertical face. Clip lap sensor cable under the instrument rail and cable tie the infra-red sensor securely to the tie. post Your kit is now ready for use as described within this manual Page 48Stare wa Lotus Service Notes a youms £1301 404 ejoy wuz 21qeo pas-eaguy 404 30/5 wy, 380d ,¥, Uo jezuozu0Yy ‘Pequnouw! 10sues pes-e1jup ‘sd)j9 91989 Jo uonysod Buymoys es juownasuy Jo apissepun dy2 9g a1qeo enssoupe yos Page 49 2000 / 02ma) Le RSA) Sire eeeN Lstaor The driver only, competition roll over bar is available for RHD or LHD cars, and is RAC approved for ‘competition use in the U.K. The roll bar is a direct replacement for the standard 340R double hoop bar, and includes an anchorage bar for the standard fit compe- tition seat belt harness shoulder straps. Fitting Instructions 1. Remove the topshell (refer to Elise Service Notes section 340R.B) and the double hoop roll-over bar. 2. _ Fitment of the new bar requires a clearance slot to be cut in the engine lid and body aperture gutter. A template (LSL401) for the engine lid slot is provided below to allow an initial ft to be made, with initial dimensions for the body aperture measureable from this. The spoiler mounting plate will also require a ‘small clearance groove to be made to allow the backstay to be connected. The body on each car will require individual fetting, but with care, no painting should be required, 3. Refit the driver's seat and seat belt hamess. Note that with this bar fitted, a passenger seat MUST NOT be fitted. Page 50@ Service Notes Sey Profile of backstay clearance siot in engine lid (actual size) RHD shown; LHD mirror image. Page 51 2000 / 02