Lotus Elise 2004, Exige 2004 User Manual
Page 1
Lotus Service Notes Introduction
CONTENTS
ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ ENGINE
Section
Technical Data - Engine TDP
- Vehicle TDQ
Chassis AH
Bodycare & Repair BQ
Body Fittings BR
Front Suspension CI
Rear Suspension DH
Engine & Engine Management - Lotus supplement EH
- Toyota 1ZZ/2ZZ engine repair manual *
* see separate manual B120T0327J
- Toyota 2ZZ-GE engine supplement #
# see separate manual C120T0327J
Engine Management EMP
Transmission - Lotus supplement FJ
- Toyota C64 transmission repair manual ~
~ see separate manual D120T0327J
- Toyota C56 transmission repair manual ^
^ see separate manual TBA
Wheels & Tyres GH
Steering HG
Brakes JJ
Engine Cooling KH
Fuel System - Except North America LJ
- North America LK
Electrics MP
Maintenance & Lubrication OI
Air Conditioning, Heating & Ventilation PL
Clutch QH
Passive Restraint (North America) WD
Supplement - Exige Supercharged (S/C) Exige S/C
Supplement - 2-Eleven 2-Eleven
Page 2
Lotus Service Notes Introduction
VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER
The Vehicle Identification Number (V.I.N.) is stamped on the chassis in the right hand front wheelarch
area, viewable with the front wheels turned to right full lock, and is also printed on a label stuck to the inside
of the chassis sideframe alongside the driver's seat. The engine number is marked on a vertical patch at the
right hand side of the rear face of the cylinder block, adjacent to the clutch housing.
Both numbers should always be quoted with any vehicle enquiries, as Factory records are filed against
V.I.N., and specification change points are identified by V.I.N. or engine number. The vehicle licence number
should be considered irrelevant, since it may not accurately reflect vehicle age, and may also be changed during the car’s life.
The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC)
and National Highway Traffic Safety Association (NHTSA) directives. For change point identification in Service
Notes, Service Bulletins and Service Parts Lists, typically, only characters 10 (model year), and 14 to 17 (serial
number) will be quoted.
'2004 M.Y. onwards
V.I.N. ON
CHASSIS
ohs119a
V.I.N. LABEL
ohs104 ENGINE NUMBER ohs133
Assembly
Plant Model
Vehicle Type H = Hethel 2 = 2-Eleven
Manufacturer 111 = Elise Check B = Shah 3 = Elise
Identifier Code 123 = 2-Eleven Digit Alam 8 = Exige
S C C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Engine Type Restraint Model Year Chassis/Body Serial
L = Motorsport A = Active belts 4 = 2004 A = LHD Fed.
Number
N = 2ZZ s/c 255 C = Dual S.I.R. 5 = 2005 C = RHD
P = 2ZZ n.a. + active belts 6 = 2006 D = LHD
V = 2ZZ s/c 7 = 2007 F = U.K. SVA RHD
Y = 1ZZ 8 = 2008 G = U.K. SVA LHD
9 = 2009 H = Motorsport*
A = 2010 J = Motorsport*
L = LHD Fed. a.c.
* Track only. Not M = LHD Can. a.c.
approved for road use N = RHD a.c.
P = LHD a.c.
Page 3
Lotus Service Notes Introduction
MODEL HISTORY MILESTONES
Elise 111R Introduction: January 2004
VIN character 4 = P; Character 13 = 3; Serial number from 0970
Note that the serial number sequence is shared with other Elise variants.
Changes from previous model include: Toyota powertrain with 1.8 litre VVTL-i engine and 6-speed transmission. Twin exhaust tailpipes exiting through centre of diffuser. Larger fuel tank with new pump. Revised
chassis rail rear ends, new rear subframe, revised seat belt mounting frame backstays. Revised rear suspension wishbones, springs and dampers. ABS brake control with vacuum servo. Revised front bonnet grilles
and access covers.
2004 Exige Introduction: March 2004
VIN character 4 = P; Character 13 = 8; Serial number from 1092
Note that the serial number sequence is shared with other Elise variants.
Differences compared with Elise 111R include: Restyled front and rear clamshells with roof scoop, new
tailgate panel and strut mounted rear aerofoil. Front body splitter panel. Re-styled road wheels, wider on the
front, and Yokohama A048 tyres.
2005 M.Y. Elise for North America: May 2004
VIN character 10 = 5; Character 12 = L; Serial number from 0001
Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for
those models later in the year.
Differences compared with Elise 111R include: Driver and passenger airbags, pyrotechnic seat belt pretensioners; Re-styled fascia and dashboard structure; Front speakers moved onto top surface of fascia, stowage pockets incorporated into dashboard end panels, fixed windscreen demist vents. Engine start button in
driver's side switch panel. Revised springs and dampers, Yokohama AD07 tyres. Side marker lamps on front
and rear wheelarch lips. Revised fuel system with fuel filler flap.
Lotus Sport Exige 240R: March 2005
Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the
Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the
VIN coding.
Differences compared to standard Exige include: 243 bhp engine upgrade using Eaton M62 supercharger
with integral by-pass valve, air/air chargecooler and 5th fuel injector. Re-programmed ECU. Accusump.
Stiffened springs & Ohlins adjustable dampers. Adjustable front anti-roll bar. Chassis rear brace kit. Forged
5-spoke widened roadwheels & Yokohama A048 tyres. Motorsport brake pads, braided hoses, yellow callipers,
Castrol SRF brake fluid. Sport Yellow body colour with black wheels, or Sport Black body with silver wheels.
Black interior with yellow inserts. 4-point harnesses, T45 roof hoop and backstays.
2006 M.Y. Introduction: September 2005
VIN character 10 = 6; Serial number restarts at 0001, common to all variants.
Introduction of USA Exige and Canadian Elise.
5-speed Elise remains unchanged.
Differences between 6-speed '06 Elise and '05 include; Electronic throttle control (using no mechanical
cable). Optional Lotus Traction Control (LTC) or Limited Slip Differential (LSD) with LTC. Standard fit Yokohama
AD07 tyres on non-USA cars. Optional forged wheels with new 6.0 in front size. LED rear lamp clusters incorporating reflectors (formerly separate), and commonised USA type CHMSL. ProBax seat foams. New body
colours. USA & Canadian Elise; revised fuel tank and evap. loss system. Canadian Elise uses daytime running
lights and clutch down start allow switch. USA Exige similar to non-USA, but with USA airbag interior.
Sports Racer: October 2005
Special paint versions of '06 M.Y. 111R in either Ardent Red with triple Monaco White stripes, or Nightfall
Blue with twin Monaco White stripes. Combined total of 199 units with unique build plate on sill. Forged wheels
(6J on front), AD07 tyres, sport suspension, twin front oil coolers, LTC. Black leather interior with red or blue
stitching, and red or blue 'Elise' embroidered into head restraints. Sports Racer decals.
Page 4
Lotus Service Notes Introduction
Exige Cup 190 & 240: January 2006
Limited number of competition oriented naturally aspirated (190) or supercharged (240) models produced
as post registration official factory conversions of '06 Exige by the Lotus Sport workshops at Hethel for U.K.
and certain overseas territories. Not identifiable from VIN coding.
Differences compared to 240R (see above) include: Electronic throttle, high flow port injectors (no 5th).
Cup 240 fitted with torque sensing LSD with LTC. Cup 190 uses friction plate LSD. Standard Exige wheels in
'Hi-power' silver. Race cars fitted with FIA 6-point roll cage, remote kill switch, extinguisher system. Standard
body colours.
Exige S: February 2006
VIN character 4 = V
Factory built type approved supercharged Exige. Not USA.
Differences to standard Exige include: 221 PS supercharged engine similar to 240R but using electronic
throttle, smooth flow inlet adaptor, standard injectors without 5th injector, modified downpipe, optimised muffler
with single oval tailpipe. Enlarged roof duct inlet for chargecooler. Body colour splitter, scoops and aerofoil.
'Exige S' decal on rear transom, 'S' on front quarter panels.
USA Lotus Sport Elise: March 2006
Limited edition of 50. Saffron Yellow with twin Storm Titanium stripes. Saffron Yellow centre console. Yel
low highlighted sports seats, 'carbon' door trim inserts. Harness bar, T45 seat belt mounting frame. Motorsport
mats, stalks, winders and parking brake sleeve. Traction control, supersport suspension, black forged wheels,
Yokohama A048s, braided brake hoses, silicone fluid, motorsport clutch. Lotus Sport decals and Union flags.
Lotus Sport chassis plate.
2007 M.Y. & Elise S Introduction: June 2006
VIN character 10 = 7; Serial number restarts at 0001, common to all variants.
VIN character 4 identifies engine type. Elise S = Y
Differences between '07 Elise/Exige and '06 include: Elise 111R renamed Elise R; New sealed headlamp
units; raised LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC ducting. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but fixed valve lift,
plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within
standard trims. Elise S also uses new C56 5-speed transmission and 6-spoke roadwheels sharing styling of
standard '01 model wheels.
USA Exige S: October 2006
The specification of the USA Exige S is that of the standard USA Exige and option packs, apart from the
engine, which is as non-USA Exige S with the following exceptions: High flow port injectors, specific engine
programming, 223 PS, 223 Nm. Carry-over features from the non-USA Exige S include exhaust downpipe and
optimised muffler with single oval tailpipe, roof air intake funnel mouth.
Exige S British GT Special Edition: November 2006
Celebrating Lotus Sport Cadena’s 2006 British GT3 Team Championship victory.
Differences to standard Exige S include: Torsen LSD & Lotus Traction Control. Chassis rear brace kit.
T45 roof hoop & stays. Braided brake hoses. Level 1 sports exhaust. Forged 7-bifurcated spoke silver wheels.
Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills,
Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique
build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow
door trims and unique black/yellow trimmed seats. Optional a.c. Optional GT pack available as post registration
official factory conversion by Lotus Sport workshops at Hethel for U.K. and certain overseas territories, includes:
High flow injectors, different ECU & unique calibration for 243 bhp, Accusump, 2-way adjustable Ohlins dampers
with uprated springs, 308mm front discs & 4-piston A.P. callipers, Pagid pads, Castrol SRF brake fluid.
Page 5
Lotus Service Notes Introduction
USA Low Speed Damage Mitigation: January 2007
From ‘07 USA VIN serial no. 1579.
To meet USA safety legislation, modifications made to Elise/Exige: Front; armatures and foam inserts
added between crash structure and clamshell. Rear; bumper panel housing foam pads either side of licence
plate, narrower rear grilles, reinforced boot floor and diffuser support panel, stiffened diffuser. Some elements
commonised for all markets.
Lotus Sport Exige Cup 255: January 2007
Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at
Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
Based on Exige Cup 240 (see above) with following differences: Power increase to 255 PS by; unique
ECU calibration, enlarged chargecooler, extended roof duct, larger air cleaner and intake spout, uprated fuel
pump. A.P. Racing 4 piston alloy front callipers, 308mm front discs.
2-Eleven Introduction: May 2007
VIN character 6/7/8 = 123; Character 13 = 2
Extreme, minimalist, track focussed Elise variant based on Exige Cup 255 powertrain componentry, but
using new chargecooler arrangement. Produced in small numbers for U.K. and certain overseas territories. In
U.K. only, SVA road going version available. All other territories only for track use, in LHD or RHD.
New body with no doors or roof. Aeroscreen. Rear aerofoil in two versions. FIA compliant roll over bar.
Chassis rear brace, unique front top wishbones and steering arms, optional Ohlins suspension. Accusump,
twin front oil coolers. Standard LTC, optional variable LTC & Launch Control. Uprated clutch. Odyssey battery.
Limited warranty for SVA cars. Extensive options list.
USA Elise Limited Edition 'Type 72D'
Limited edition of 50 cars to commemorate the 35th anniversary of Lotus' F1 1972 World Championship
victory with the type 72D.
Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold
laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black
nosebadge, gold fuel filler cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspension. Black & gold seats and interior trim details with Limited Edition plaque. Scale model crash helmet.
Page 6
Lotus Service Notes Introduction
ENGINE BAY UNDERTRAY/DIFFUSER
For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser
panel. The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay
clean. Do not run the car without the panels fitted.
3 screws to licence 1 screw each side
plate plinth to grille panel
b275b
Diffuser panel
3 screws
each side
Single screw each to tank bay
side to clamshell panel
Undertray
front edge
M8 button head slots into
(2) to subframe 5 screws M8 button head chassis
undertray (2) to lower
to diffuser link brackets
Page 7
Lotus Service Notes Introduction
JACKING POINTS
Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas
shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a
4-point lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using
a 4-point lift, it is strongly recommended that for optimum stability and safety, positions B and D are used.
A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time
for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift.
B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use
with 4-point lift in conjunction with (C).
C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis
crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws
for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B).
D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower
wishbone rearmost mountings.
Jacking at any other point may damage the chassis or body structure and/or jeopardise safety.
ohs49sn
Page 1
Lotus Service Notes Section TDP
TECHNICAL DATA - ENGINE
SECTION TDP
Page
General .................................................................................................................... 2
Cylinder Block .......................................................................................................... 2
Cylinder Head .......................................................................................................... 3
Valves & Springs ...................................................................................................... 3
Camshafts ................................................................................................................ 3
Pistons ..................................................................................................................... 3
Connecting Rods ...................................................................................................... 3
Crankshaft ............................................................................................................... 3
Oil Pump .................................................................................................................. 3
Coolant Thermostat .................................................................................................. 3
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Lotus Service Notes Section TDP
GENERAL
Type designation - All except Elise S 2ZZ-GE
- Elise S 1ZZ-FE
Configuration & no. of cylinders in-line 4 Capacity 1796 cm3 1794 cm³
Bore 82.00 mm 79.00 mm
Stroke 85.00 mm 91.50 mm
Camshafts Chain driven DOHC Valves 4VPC in pentroof chambers
Valve control - inlet Variable timing & lift Variable timing
- exhaust Variable lift Valve timing - inlet - low & medium speed - open 33° BTDC to all speeds 48° BTDC
to 10° ATDC to 5° BTDC
- close 15° ATDC to all speeds 12° ATDC
58° ATDC to 55° ATDC
- high speed - open 58° BTDC to
15° BTDC
- close 54° ABDC to
97° ABDC
- exhaust - low & medium speed - open 14° BBDC all speeds 42° BBDC
- close 34° ATDC all speeds 2° ATDC
- high speed - open 36° BBDC
- close 60° ATDC
Compression ratio 11.5:1 10.0:1
Compression pressure (250 rpm) - new 1400 kPa (203 psi) 1500 kPa (218 psi)
- service limit 1000 kPa (145 psi) Firing order 1,3,4,2 Spark plugs NGK IFR6A11 NGK BKR5EYA-11
Spark plug gap 1.1 mm 1.0 ± 0.05 mm
Maximum continuous engine speed 8000 rpm 6,800 rpm
Maximum transient engine speed 8500 rpm 7,000 rpm
Idle speed 850 rpm Ignition system Direct ignition using individual H.T. coils
for each cylinder
Fuel system Fully sequential indirect fuel injection,
Lotus T4 controller
Fuel requirement (minimum) Unleaded 95 RON Peak power (1999/99/EC) 141 kW (192 PS) 100 kW (136 PS)
@ 7,800 rpm @ 6,200 rpm
Peak torque (1999/99/EC) 181 Nm 172 Nm
@ 6,800 rpm @ 4,200 rpm
Exhaust emissions - CO 0.42 g/km 0.23 g/km
- HC 0.078 g/km 0.050 g/km
- NOx 0.0121 g/km 0.0217 g/km
- HC + NOx 0.0792 g/km 0.0717 g/km
- CO2 208 g/km 196 g/km
CYLINDER BLOCK
Material Aluminium alloy, Aluminium alloy,
MMC cylinder bores cast iron liners
Deck face flatness tolerance 0.05 mm Cylinder bore diameter 82.000 - 82.013 mm 79.000 - 79.013 mm
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Page 3
Lotus Service Notes Section TDP
CYLINDER HEAD 2ZZ-GE 1ZZ-FE
Material Aluminium alloy Head face flatness tolerance 0.05 mm Reface limit No machining -
VALVES & SPRINGS
Valve seat angle in head 45° Valve face angle 44.5° Cold valve clearance (between cam & follower) - inlet 0.10 - 0.16 mm 0.15 - 0.25 mm
- exhaust 0.24 - 0.30 mm 0.25 - 0.35 mm
Valve guide standout 15.3 - 15.7 mm 8.7 - 9.1 mm
Valve spring free length - inlet 46.4 mm 45.9 mm
- exhaust 46.5 mm 45.9 mm
CAMSHAFTS
End float - new 0.04 - 0.14 mm 0.04 - 0.10 mm
- service limit 0.15 mm 0.11 mm
PISTONS
Diameter - @ 90° to pin, 12 mm from bottom edge 81.975 - 81.993 mm
- @ 90° to pin, 25 mm from top edge 78.925 - 78.935 mm
Ring gap, 110 mm from block top face - std. - no.1 0.25 - 0.35 mm -
- no.2 0.35 - 0.50 mm -
- oil rail 0.15 - 0.40 mm -
- max. - no.1 1.1 mm -
- no.2 1.2 mm -
- oil rail 1.1 mm Ring groove clearance 0.030 - 0.070 mm -
CONNECTING ROD
Small end bush inside diameter 20.011 - 20.023 mm 20.012 - 20.021 mm
Big end side clearance 0.16 - 0.34 mm -
CRANKSHAFT
Crankshaft endfloat - new 0.04 - 0.24 mm -
- service limit 0.30 mm Main journal diameter 47.988 - 48.000 mm Crankpin diameter 44.992 - 45.000 mm 43.992 - 44.000 mm
Max. taper & out of round, journals & crankpins 0.02 mm -
OIL PUMP
Oil pressure - idle, running temperature 39 kPa (6 psi) min. 29 kPa (4 psi) min.
- 3,000 rpm, running temperature 300 - 540 kPa (45 - 80 psi)
Outer rotor to housing clearance - new 0.13 - 0.18 mm -
- service limit 0.33 mm Inner rotor tip clearance - new 0.06 - 0.18 mm -
- service limit 0.33 mm Rotor end float - new 0.03 - 0.08 mm -
- service limit 0.16 mm -
COOLANT THERMOSTAT
Valve opening temperature 80 - 84°C Valve lift at 90°C 10 mm Header tank pressure cap 108 kPa Cap opening pressure 93 - 123 kPa -
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Lotus Service Notes Section TDP
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Page 5
Lotus Service Notes Section TDP
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Lotus Service Notes Section TDQ
TECHNICAL DATA - VEHICLE
SECTION TDQ
Page
Dimensions ........................................................................................................ 2
Capacities .......................................................................................................... 2
Wheels & Tyres ................................................................................................... 3
Front Suspension ................................................................................................. 3
Rear Suspension ................................................................................................. 4
Electrical ............................................................................................................. 5
Transmission ....................................................................................................... 5
Clutch .................................................................................................................. 6
Brakes ................................................................................................................. 6
Steering ............................................................................................................... 6
Fuel Consumption ............................................................................................... 6
Page 1
Lotus Service Notes Section TDQ
DIMENSIONS
Overall length - Elise 3785 mm
- Exige 3797 mm
Overall width - exc. mirrors - Elise 1719 mm
- Exige 1727 mm
- inc. mirrors 1850 mm (approx.)
Overall height (at kerb weight) - Elise 1117 mm
- Exige 1159 mm
Wheelbase 2300 mm
Track - front 1457 mm
- rear 1507 mm
Ground clearance (mid-laden) - except std. USA 130 mm
- std. USA 135 mm
Front overhang - Elise 783 mm
- Exige 805 mm
Rear overhang - Elise 702 mm
- Exige 692 mm
Approach angle (at kerb) 13.5°
Departure angle (at kerb) 23°
Unladen weight - 111R/Elise R - total 860 kg >
(lightest) - front 327 kg > incl. full fuel tank
- rear 533 kg >
- Elise S - total 862 kg }
(lightest) - front 328 kg } incl. full fuel tank
- rear 534 kg }
- USA Elise - total 912 kg )
(heaviest) - front 344 kg ) incl. full fuel tank
- rear 568 kg )
- non-USA Exige - total 875 kg >
- front 328 kg > incl. full fuel tank
- rear 547 kg >
- non-USA Exige S- total 935 kg }
- front 355 kg } incl. full fuel tank
- rear 580 kg }
- USA Exige - total 920 kg )
- front 350 kg ) incl. full fuel tank
- rear 570 kg )
Max. weight - 111R/R, Exige - total 1166 kg >
- front 443 kg > incl. occupants & luggage
- rear 723 kg >
- Elise S - total 1126 kg }
- front 428 kg } incl. occupants & luggage
- rear 698 kg }
- USA Elise - total 1162 kg )
- front 441 kg ) incl. occupants & luggage
- rear 721 kg )
- non-USA Exige S- total 1199 kg >
- front 456 kg > incl. occupants & luggage
- rear 743 kg >
Trailer towing Not permissible
CAPACITIES
Engine oil - refill inc. filter 4.4 litre
(+ 3.5 litre if front mounted oil coolers are drained)
High/low dipstick mark difference 1.5 litre
Transmission oil 2.3 litre
Fuel tank 43.5 litre
Page 2
Lotus Service Notes Section TDQ
Coolant 12 litre
Refrigerant 550 g
Rear luggage compartment 50 kg/112 litre
WHEELS & TYRES
Tyres
Type - Elise std. - prior '06 Bridgestone Potenza RE040
- from '06 Yokohama Advan Neova AD07
- USA Elise Yokohama Advan Neova AD07
- Elise option, Exige Yokohama A048
Size - front - Elise std. 175/55 R16 80W
- USA Elise 175/55 R16 80W
- Elise option, Exige 195/50 R16 84W
- rear - Elise std. - RE040 225/45 R17 90W
- AD07 225/45 R17 91W
- USA Elise - AD07 225/45 R17 91W
- Elise option, Exige - A048 225/45 R17 90W
Pressure (cold) - front 1.8 bar (26 lb/in²)
- rear 2.0 bar (29 lb/in²)
Winter Tyres
Type - front Pirelli 210 Snowsport
- rear Pirelli 240 Snowsport
Size - front 195/50 R16
- rear 215/45 R17
Pressure (cold) - front 1.8 bar (26 lb/in²)
- rear 1.9 bar (27.5 lb/in²)
Tyre studding Not permitted
Tyre chains Pewag Neon X3-NX373
fitted only on rear winter tyres
Wheels
Type - Elise 111R/R/USA Cast alloy, 8 spoke
- Elise S Cast alloy, 6 spoke
- Exige std. Cast alloy, 8 Y-spoke
- Elise/Exige option Forged alloy, 7 split-spoke
Size - front - Elise std. 5.5J x 16
- Elise option 6.0J x 16 (forged + AD07)
- Elise option, Exige 6.5J x 16 (forged + A048)
- rear 7.5J x 17
Wheel bolt torque 105 Nm (77 lbf.ft)
FRONT SUSPENSION
Type Independent. Upper and lower wishbone; co-axial
coil spring/telescopic damper unit; anti-roll bar
Steering axis inclination 12 ° nominal
Geometry specification - Standard Elise:
Mid-laden ride height (reference height for geometry check)
- USA Elise from VIN 3013 & 111R/R/S - front 130 mm below front end of chassis siderail
- rear 130 mm below rear end of chassis siderail
- USA Elise prior VIN 3013 - front 135 mm below front end of chassis siderail
- rear 135 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Page 3
Lotus Service Notes Section TDQ
Camber - optimum - 0.1°
- tolerance range + 0.1° to - 0.3°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.7mm toe-in overall
Geometry specification - Sportpack Elise, Exige:
Mid-laden ride height (reference height for geometry check)
- front 130 mm below front end of chassis siderail
- rear 130 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.3°
- tolerance range - 0.1° to - 0.5°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.5 mm toe-in overall
Geometry specification - Supersportpack Elise, Exige:
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail
- rear 120 mm below rear end of chassis siderail
Castor - optimum + 3.8°
- tolerance range + 3.5° to + 4.1°; max. side/side 0.35°
Camber - optimum - 0.2°
- tolerance range + 0.1° to - 0.3°; max. side/side 0.2°
Alignment - optimum Zero
- tolerance range 0.5 mm toe out, to 0.7 mm toe-in overall
REAR SUSPENSION
Type Independent. Upper and lower wishbone; co-axial
coil spring/telescopic damper.
Geometry specification - Standard Elise:
Mid-laden ride height (reference height for geometry check)
- USA Elise from VIN 3013 & 111R/R/S - front 130 mm below front end of chassis siderail
- rear 130 mm below rear end of chassis siderail
- USA Elise prior VIN 3013 - front 135 mm below front end of chassis siderail
- rear 135 mm below rear end of chassis siderail
Camber - optimum - 1.8°
- tolerance range - 1.6° to - 2.0°; max.side/side 0.2°
Alignment - optimum 1.2 mm toe-in each side
- tolerance range 1.2 to 1.8mm toe-in each side
max.side/side 0.3 mm
Geometry specification - Sportpack Elise, Exige:
Mid-laden ride height (reference height for geometry check)
- front 130 mm below front end of chassis siderail
- rear 130 mm below rear end of chassis siderail
Camber - optimum - 1.8°
- tolerance range - 1.6° to - 2.0°; max.side/side 0.2°
Alignment - optimum 1.5 mm toe-in each side
- tolerance range 1.2 to 1.8 mm toe-in each side
max.side/side 0.3 mm
Geometry specification - Supersportpack Elise, Exige:
Mid-laden ride height (reference height for geometry check)
- front 120 mm below front end of chassis siderail
- rear 120 mm below rear end of chassis siderail
Page 4
Lotus Service Notes Section TDQ
Camber - optimum - 2.5°
- tolerance range - 2.0° to - 2.7°; max.side/side 0.2°
Alignment - optimum 1.8 mm toe-in each side
- tolerance range 1.5 to 2.0 mm toe-in each side
max.side/side 0.3 mm
ELECTRICAL
Light Bulbs Wattage Type
Headlamps - prior '07 - main beam 55 H7
- dip beam 55 H1
- from '07 - main beam 55 H7U
- dip beam 55 H7U
Driving lamps 55 H3
Front side/parking lamps 5 W5W
Side repeater lamps 5 WY5W amber
Front turn indicators 21 PY21w amber
Rear turn indicators - prior '06 21 H21 )
Stop/Tail lamps - prior '06 4/21 P21/4w )
Stop lamps (USA) - prior '06 21 H21 ) '06 onwards use
Tail lamps - prior '06 5 R5W ) LED clusters
Tail/turn lamps (USA) - prior '06 4/21 P21/4w )
Fog/Tail lamps - prior '06 4/21 P21/4w
Reversing lamp - prior '06 21 H21
Turn lamps (non-USA) - from '06 16 W16W
Reverse lamps - from '06 16 W16W
High mounted stop lamp 2.5 16 x LED
Licence plate lamps 5 C5W
Interior lamp 5 W5 W
System voltage/polarity 12V negative earth
Alternator 85A
Battery - non USA - type Yuasa 063/3
- cranking power (SAE) 380A
- reserve capacity 70 minutes
- dimensions (mm) L 207, W 175, H 175
- USA - type Delco 19001598
- BCI code 26R-6YR
- cranking power 550 amps @ -18°C
- reserve capacity 80 minutes
TRANSMISSION
Gearbox - all except Elise S 6-speed manual incl. final drive
- Elise S 5-speed manual incl. final drive
Differential - standard Open, bevel gear
- option Torsen type LSD with Lotus Traction Control
Gear Ratio Final Drive mph(km/h)/1000 rpm
5-speed 6-speed 5-speed 6-speed 5-speed 6-speed
First 3.17 : 1 3.17 : 1 ) 5.36 (8.62) 5.1 (8.2)
Second 1.90 : 1 2.05 : 1 ) 8.73 (14.1) 7.7 (12.4)
Third 1.39 : 1 1.48 : 1 ) 4.31 : 1 4.53 : 1 12.0 (19.2) 10.7 (17.2)
Fourth 1.03 : 1 1.17 : 1 ) 16.2 (26.0) 13.6 (21.8)
Fifth 0.82 : 1 0.92 : 1 ) 20.4 (32.8) 17.3 (27.8)
Sixth - 0.81 : 1 ) - 19.4 (31.3)
Reverse 3.25 : 1 3.25 : 1 )
Page 5
Lotus Service Notes Section TDQ
CLUTCH
Type Single dry plate. Diaphragm spring cover.
Hydraulic release.
Friction plate diameter 215 mm
Diaphragm finger clearance 1.00 mm
Diaphragm finger height - new 37.5 - 32.1 mm
- service limit 42.75 mm
Friction plate thickness - new 7.4 - 6.9 mm
- service limit 5.6 mm
Rivet depth - new 1.00 mm
- service limit 0.20 mm
Friction plate run-out - new 0.80 mm
- service limit 1.00 mm
Pressure plate warp - service limit 0.15 mm
BRAKES
Brake discs Cast iron, curved vane ventilated, cross-drilled discs
on all four wheels.
Calipers - front A.P. Racing, aluminium alloy body, one pair of
opposed pistons
- rear Brembo, cast iron, single piston sliding rear calipers
Disc size - front & rear 288 mm
Operation Tandem master cylinder with vacuum servo and
Kelsey Hayes EBC430 Anti-lock system
Parking brake Cable operation of rear calipers, self adjusting for
pad wear .
STEERING
Type Rack and pinion
Turns, lock to lock 2.8
Gear ratio 15.8:1
Rack height plate 6 notch
FUEL CONSUMPTION 1ZZ-GE 2ZZ-GE
1999/100/EC - urban 1 1.3 l/100km 12.1 l/100km
- extra urban 6.5 l/100km 6.8 l/100km
- combined 8.3 l/100km 8.8 l/100km
Page 6
Page 1
Lotus Service Notes Section AH
CHASSIS
SECTION AH
Sub-Section Page
General Description AH.1 3
Chassis Straightness Check AH.2 4
Rear Subframe AH.3 5
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Page 2
Lotus Service Notes Section AH
ELISE CHASSIS UNIT
Seat belt mounting
frame steel roof hoop
Composite Scuttle Seat mounting
crash structure beam extrusion Seat belt mounting
frame backstay
Door hinge
mounting
Sill extrustion
Main siderail
Fuel tank bay Steel rear subframe
a29b
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Page 3
Lotus Service Notes Section AH
AH.1 - GENERAL DESCRIPTION
The chassis frame of the Lotus Elise is constructed primarily from aluminium alloy extrusions and formed
alloy sheet, with the various sections bonded together using an epoxy adhesive with secondary drive-in fasten
ers. The basic chassis unit includes the passenger cell, front suspension mountings, fuel tank housing, and mid
mounted engine bay, with a fabricated sheet steel rear subframe bolting to the rear of the engine bay to provide
rear suspension mountings and rear body support. A tubular steel seat belt mounting frame is bolted to the top of
the chassis structure and incorporates a roof hoop for additional occupant protection. The cabin rear bulkhead,
body sills (inc. 'B' posts), front energy absorbing crash structure and scuttle/windscreen mounting frame, are all
constructed from glass fibre composite and are bonded to the chassis structure using an elastomeric adhesive.
The front and rear outer body clamshells are each constructed from glass fibre composite mouldings, fixed to
the body and chassis structure with threaded fasteners to facilitate service access and economic repair.
Two main chassis siderail extrusions, 210mm deep and 100mm wide, run along each side of the passenger
compartment between the front and rear suspension mountings, splaying outwards towards the rear before
curving inwards around the fuel tank bay and terminating at each side of the engine bay in a vertical section to
provide engine mounting platforms and a flange to which the rear subframe is attached. To enhance cockpit
access, the height of the siderails is reduced in the door area, and internal reinforcement added in order to
maintain beam strength and torsional rigidity.
Running along the underside of the siderails from the front suspension crossmember to the fuel tank bay
are sill extrusions which carry the cockpit floor panel. The single skin floor panel is swaged for stiffness, and
is reinforced by a ribbed transverse extrusion running across the inside of the tub, which also provides for the
seat mountings. Behind the passenger cell, the siderails are linked by a pair of transverse crossmembers
which are used in conjunction with a folded sheet upper panel to form an open bottomed fuel tank cell with a
detachable, screw fixed, closing panel with swaged lightening holes. Note that this lower panel contributes to
the structural integrity of the chassis, such that the vehicle should not be operated without it fitted.
The rear ends of the siderails are joined behind the engine bay by a galvanised sheet steel fabricated
subframe which provides mountings for the rear suspension pivots nad damper abutment, engine rear stabiliser
and exhaust muffler.
At the front of the passenger compartment, four transverse extrusion beams are used to provide mountings
for the front suspension pivots, and house the steering rack, with an upright section used each side to anchor
the top of the spring/damper unit. Five interlinked extruded floor sections together with additional extrusions,
connect the transverse beams to form an open topped space to house the heater/a.c. unit. An extruded scuttle beam links the tops of the siderails at the front of the cockpit, and is reinforced by a panel extending to the
steering rack crossmember. These elements are used to mount the steering column and pedal box, with a
vertical extrusion fixed to each end of the scuttle beam to carry the door hinge pillar.
To the front end of the chassis is bonded a glass fibre composite 'crash structure' which incorporates
tubular sections designed to dissipate collision energy and control the rate of deceleration sustained by the
occupants. Ducting and mountings for the horizontally positioned engine cooling radiator are also incorporated
in this structure.
The bonded and rivetted alloy chassis structure described above is considered a non-serviceable single
unit, jig built to fine tolerances, to which no structural repairs are approved. Superficial, cosmetic, or non-structural
localised damage may be cosmetically repaired as necessary, but in the case of accident damage resulting in
significant bending, tearing or distortion of the aluminium chassis, such that the specified suspension geometry cannot be achieved by the standard range of suspension adjustment provided, the recommended repair
is to renew the partial body assembly, which comprises the chassis, rear subframe and the seat belt mounting
frame together with jig bonded composite rear bulkhead, body sills, windscreen frame and crash structure.
Also included are the radiator feed and return pipes in the chassis siderails, and those pipes and cables routed
through the sills, including the heater and a.c. pipes, battery cable, clutch and brake pipes, and brake servo
and oil cooler hoses.
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Page 4
Lotus Service Notes Section AH
AH.2 - CHASSIS STRAIGHTNESS CHECK
In the absence of visual damage, the chassis may be checked for twist or distortion by utilising the tooling
holes in the underside of the main side rails. If computer processed laser measuring equipment is not avail
able, manual checks can be made with reference to an accurately level ground plane, e.g. an accurately set
and maintained suspension geometry ramp/lift. Position the car on the lift, and proceed as follows:
1. Identify the tooling holes in the lower surface of each chassis main side rail. At the front end, between the
suspension wishbone pivots, and at the extreme rear end of each rail.
2. Measure the height of each tooling hole above the reference plane and use jacks to adjust the height of
the chassis in order to equalise any three of these dimensions.
3. Measure the deviation of the fourth dimension from the other three.
Maximum service deviation = ± 2.0 mm.
4. Repeat operations (2) and (3) for each combination of corners to result in four values for the 'fourth' dimen
-
sion deviation. If any one of these exceeds the service specification, the chassis should be considered
damaged and replaced by a partial body assembly.
FRONT REAR
Tooling hole
Tooling
hole
Front wishbone Rear wishbone
a27/27a
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Page 5
Lotus Service Notes Section AH
AH.3 - REAR SUBFRAME
The rear ends of the chassis siderails are linked by a fabricated sheet steel subframe which provides
mountings for the rear body section, rear suspension pivots, engine rear stabiliser, exhaust muffler and seat
belt mounting frame struts. The subframe is secured to the siderails by two M12 bolts at each side, with an
anti-corrosion shim plate interposed.
To remove rear subframe
1. Remove the rear clamshell (see section BR).
2. Remove exhaust heatshields, catalytic converter and muffler.
3. Disconnect the parking brake cables, wheel speed sensor harnesses and rear brake hydraulics. Release
the driveshafts from the hubs, and remove both rear suspension assemblies complete, providing alterna
-
tive support for the driveshafts.
4. Disconnect the inertia switch, and release from the subframe the oxygen sensor harness, wheel speed
sensor harnesses and brake pipes.
5. Release the engine rear stabiliser mounting from either the subframe or transmission.
6. Release the roof hoop backstays from the subframe. Remove the two bolts each side securing the sub
-
frame to the chassis flange and withdraw the subframe from the car.
Fitting rear subframe
When bolting the subframe at each side to the chassis rail rear flange, ensure that the anti-corrosion
shim plate is interposed. The lower fixing bolts should be inserted from the rear, using a washer and Nyloc nut
inside the chassis extrusion. Apply Permabond A130 (A912E7033V) to the threads of the upper bolts before
fitting from the front into the weldnuts in the subframe. Tighten all four bolts to 86 Nm. Continue re-assembly
in reverse order to disassembly.
Seat belt mounting
frame backstay
Backstay to subrame
fixing bolt
Subframe upper
mounting bolt Rear subframe
Chassis
a30
Anti-corrosion shimplate Subframe lower mounting bolt
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Page 1
Lotus Service Notes Section BQ
BODYCARE & REPAIR
SECTION BQ
Sub-Section Page
General Description BQ.1 3
Lotus Composite Body Features BQ.2 3
Bodycare BQ.3 4
Accident Damage Assessment BQ.4 5
Body Panel Bonding Materials BQ.5 6
Replacement of Bonded-On Panels - General BQ.6 9
Front Crash Structure BQ.7 10
Windscreen Frame BQ.8 12
Sill Panels BQ.9 16
Rear Bulkhead BQ.10 17
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Page 2
Lotus Service Notes Section BQ
Body Panels
Door
shell
Windscreen Sill panel
Front access frame
panel Rear
window
shroud
Engine
cover lid
Front
clamshell
Cabin rear
Door hinge bulkhead
cover panel
Rear clamshell
Front crash
structure
Chassis frame
b277b
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Page 3
Lotus Service Notes Section BQ
BQ.1 - GENERAL DESCRIPTION
The body panels of the Lotus Elise are constructed of composite materials, with the external panels not
being required to contribute to chassis rigidity. The panels are attached to the aluminium chassis and/or other
body panels either by elastomeric polyurethane adhesive, or in the case of the front and rear clamshells, are
bolted on for ease of dis-assembly and access to chassis parts. The composite mouldings are manufactured
by one of several processes (see later) dependent on application, with a nominal thickness of 2.2 - 2.5 mm.
The windscreen frame incorporates foam beams to create closed box sections for optimum strength and a
‘crash structure’ bonded to the front of the chassis incorporates longitudinal box sections to provide specific
crush characteristics and absorb crash impact by progressive collapse. This structure also acts as a mounting
and duct for the engine cooling radiator which is mounted horizontally on its top surface.
BQ.2 - LOTUS COMPOSITE BODY FEATURES
Composite structures have the ability to absorb high impact loads by progressive collapse, with impact
damage being localised. In vehicle accidents this feature protects the occupants from injurious shock loads and
greatly reduces the danger of entrapment by deformation of steel body panels. This behaviour also facilitates
repair by either replacing the damaged bonded or bolt on panels, and/or integrating a replacement section
with the undamaged area, using recognised approved methods which restore the panel to its original condition
without residual strain or distortion.
The manufacturing process enables the thickness of composite mouldings to be varied in order to provide
efficient 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 features an assembly of mouldings to form a single piece for the whole of the nose and front wings,
and a similar assembly for the whole of the rear body aft of the doors. These two 'clamshells' are fixed using
threaded fasteners 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 compartment
lid, windscreen frame and rear bulkhead, some panels being bonded to the aluminium alloy chassis with an
elastomeric adhesive.
A composite panel may return to its original shape after deflection, but beyond a certain level of flexibility,
such treatment may result in the formation of surface cracks which may not be immediately apparent due to
the masking effect of the paint film. A steel panel similarly treated would become dented or deformed. The
cracking may be confined to the surface layer with no reduction in panel strength, but if the damage is more
severe the composite structure below the surface may be weakened. Localised repairs can be made in either
case. Possible causes of surface cracking include:
- Vehicle collision;
- Sitting, leaning heavily or pushing on the body or any composite panel;
- Knocking doors against obstructions when opening;
- Dropping objects onto a panel;
- Allowing unrestrained items to roll about in a luggage compartment;
- Fitting a front access panel or closing the engine cover onto projecting objects, e.g. luggage or tools;
- Applying excessive force to parts attached to composite panels e.g. mirrors, locks, aerial etc. (inc. action
byvandals).
- Incorrect jacking.
The composite body panels of the Elise are manufactured by one of several processes dependent on the
requirements of the panel concerned:
- The front and rear clamshells, sill panels, windscreen frame, door outer panels, hard top roof outer panel
and front crash structure are produced by Injection Compression System Resin Transfer Moulding (ICS
RTM), whereby a mix of polyester resin and glass fibres is injected into a heated, chrome steel surfaced,
closed mould. After filling, the gap between the two halves of the mould is then reduced in order to compress the moulding and ensure complete material flow and consistent structural quality. Panel thickness
is a nominal 2.2 mm. The absence of the 'gel coat' used with other processes results in much greater
resistance to surface damage, and minimum surface preparation for before painting.
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Page 4
Lotus Service Notes Section BQ
- The front access panels, engine cover lid, door hinge panels, door and roof inners and rear window shroud
are produced from Low Pressure Sheet Moulding Compound (LPSMC), whereby flat sheets of composite
material are formed using heated, chrome steel surfaced moulds to produce panels with a nominal thickness of 2.5 mm.
- A third process is used for the cabin rear bulkhead, bootbox and radiator mounting panel where the panel
surface is not primarily visible. These panels are produced by a Polyurethane Structural Reaction Injection Moulding (PU SRIM) process.
- Body panels unique to the Exige model, including front and rear clamshells, door hinge cover panels and
tailgate panel, are 'hand lay' composite mouldings with a nominal thickness of 2.5 mm.
Whichever production process applies, conventional composite repair techniques can be used to rectify
structural or surface damage whenever repairs can be determined as being more economic than panel replacement.
BQ.3 - BODYCARE
The acrylic enamel paint finish of the Elise is extremely resistant to all normal forms of atmospheric attack.
Following the simple maintenance procedure summarised below will help retain the gloss, colour and protective
properties of the paint throughout the life of the vehicle. However, car finishes are not immune to damage, and
amongst the more common causes of deterioration are:
- Atmospheric contaminants; dust, soot, ash, and acidic or alkaline aerosol mist can chemically attack
paint.
- Abrasion; blowing sand and dust, or a dirty washing cloth.
- Tree sap and insect fluids; can form a water-insoluble polymer that adheres to the paint.
- Bird excrement; highly acidic or alkaline, they can chemically etch the paint. Wash off immediately.
- Leaves; contain tannic acid which can stain light finishes.
- Impact damage; granite chippings thrown up from poor or recently dressed road surfaces can subject the
body to severe localised impact, and result in paint chips, especially around the vulnerable frontal panels.
Do not follow other vehicles too closely in such circumstances.
Washing
Lotus recommends that the car be hand washed, using the following instructions:
Many contaminants are water soluble and can be removed before any harm occurs by thorough washing
with plenty of lukewarm water, together with a proprietary car wash additive (household detergent and washing
up liquid can contain corrosive salts, and will remove wax and accelerate oxidation). Frequent washing is the
best safeguard against both seen and invisible contaminants. Wash in the shade, and use a cotton chenille
wash mitt or a sponge rinsed frequently to minimise entrapment of dirt particles. Use a straight back and forth
washing motion to avoid swirled micro scratches, and rinse thoroughly.
In order to minimise degradation from road salt, the underside of the chassis should be rinsed with clean
water as soon as possible after driving on treated roads. Many fuel filling stations offer pressure washing facilities ideal for this purpose, but to not use on the painted bodywork or soft top roof.
Soft Top Roof:
1. Careful vacuuming of the soft top before washing may be helpful in removing excess dust and other foreign
particles.
2. Wash in partial shade rather than strong sunlight, and wet the whole car before tackling the soft top.
3. Using only clean lukewarm water and a sponge (a chamois or cloth will leave lint, and a brush may abrade
the threads) wash the entire top uniformly. Do NOT use a detergent, which may affect the waterproofing
properties of the material.
4. Rinse the whole car to remove all soap from the fabric and to prevent streaking on the car bodywork.
5. Remove surface water with a sponge and allow to air dry in direct sunlight. Ensure that the roof is fully dry
before stowing, as prolonged stowage of a wet or damp roof will promote rotting of the fabric.
Keeping the soft top clean by regular washing will enhance the life and maintain the appearance of the
roof, and facilitate subsequent cleaning. The use of stronger cleansers should be left to professionals experi-
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Page 5
Lotus Service Notes Section BQ
enced in handling this type of fabric as discoloration and degradation of the special protective inner layer may
result. The application of wax finishes, dressings or preservatives will cause stains which are difficult to remove
and therefore should be avoided.
Paintwork Polishing
Eventually some loss of gloss, and an accumulation of traffic film, will occur. At this stage, after normal
washing, the application of a good quality liquid polish will restore the original lustre of the paint film. Higher
gloss of the paint finish, and added protection against contamination, can be obtained by the use of a wax
polish; however, this can only be used successfully on a clean surface, from which the previous application has
been removed with white spirit or a liquid polish cleaner.
Ventilation
Water lying on the paint surface for a lengthy period will eventually penetrate the paint film. Although the
effects will not be visible immediately, a deterioration in the protective properties of the paint film will ultimately
result. It is not recommended to store a wet car in a poorly ventilated garage. If good ventilation cannot be
provided, storage outside on a hard standing or under a carport is to be preferred.
BQ.4 - ACCIDENT DAMAGE ASSESSMENT
The repair method to be employed in the rectification of accident damage to composite panels, is to be
assessed reletive to the particular panel and its method of attachment:
Bolt-on Panels: - Front Clamshell;
- Rear Clamshell;
- Door Shells;
- Front Body Access Panels;
- Engine Cover Lid;
- Door Hinge Cover Panels;
- Rear Window Shroud;
- Hard Top Roof.
These panels are secured by threaded fasteners and are easily removed for access to the back of any
damaged area for repair by conventional composite techniques. Instructions for the removal and refitment of
these panels are contained in section BR.
Bonded-on Panels: - Windscreen Frame;
- LH & RH Sill Panels;
- Front Crash Structure;
- Rear Bulkhead
These panels are bonded to the chassis or to other panels using a flexible polyurethane adhesive which
must be cut before the panel may be removed. In some cases, it may be necessary to partially remove another
panel before the subject panel can be released. It is not generally economic to attempt to remove a bonded
panel intact for later re-fitment.
The integrity of the front crash structure is crucial to the safety of the car in a frontal collision, and it is rec-
ommended not to attempt any major repair of this component. The damaged structure should be cut from the
front of the chassis, and a new assembly bonded into position. The shape and positioning of the windscreen
frame is crucial to the fit of the windscreen and sealing of the soft top roof, such that the only repairs which
should be considered for this panel are cosmetic and superficial; any structural damage should entail panel
replacement.
The sill panels include the ‘A’ and ‘B’ posts, and involve much labour time to replace. Localised repairs
should be performed whenever possible, although access to the inside surface of some parts of the panels is
not freely available.
Note that if damage is such as to require replacement of the chassis, replacement chassis assemblies are
provided only as a 'partial body assembly' which includes jig bonded front crash structure, windscreen frame,
side sills and rear bulkhead. The roof hoop and rear subframe are also included, as are the pipes, hoses and
cables routed through the sills.
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Page 6
Lotus Service Notes Section BQ
BQ.5 - BODY PANEL BONDING MATERIALS
The materials used for bonding the body panels are manufactured by Dow Chemical, and in order to
maintain the structural integrity of the vehicle, and in the case of the front crash structure, the safety, it is most
important to use only the specified materials. The surface preparation and cleaning and priming operations are
crucial to the performance of the adhesive, and must be followed in detail. The products to be used depend on
the surface (substrate) onto which they are applied, and the following list identifies each application:
Anodised aluminium (e.g. chassis and components)
Cleaner: Betawipe VP 04604 Lotus part no. A082B6150V
Primer: Betapnme 5404 Lotus part no. A082B6337V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Unpainted or painted composite
Cleaner: Betaclean 3900 Lotus part no. A100B6008V
Primer: Betaprime 5404 Lotus part no. A082B6337V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Zinc plated and passivated steel
Cleaner: Beatclean 3900 Lotus part no. A100B6008V
Primer: Betaprime VP 01706 A+B Lotus part no. A100B6070V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
Glass
Cleaner: Betawipe VP 04604 Lotus part no. A082B6150V
Primer: Betaprime 5001 Lotus part no. A100B6009V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Uncoated Lexan/Perspex
Cleaner: Abrasion & dry wipe
Primer: Betapnme 5404 Lotus part no. A082B6337V
Adhesive: Betaseal 1701 Lotus part no. A082B6281F
or Betamate E2400 Lotus part no. A082B8415V
Residual adhesive (i.e. rebonding to surface after cutting off old panel)
Cleaner, primer
& re-activator: Betawipe 4000 Lotus part no. A082B6355V
Adhesive: Betaseal 1701 Lotus part no. A082B6281 F
or Betamate E2400 Lotus part no. A082B8415V
Applicator Bottle
An applicator bottle is available for use with some cleaners and primers, and has a disposable felt pad
which should be changed regularly to minimise surface contamination:
Applicator bottle: A000Z1071F
Cap: A082B6353S
Felt pad: A082B6354S
Product Usage
BETAWIPE VP 04604 (A082B6150V):
Description: Activator and cleaning agent used to promote adhesion to the substrate surface. Supplied in
a 250ml aluminium container with a YELLOW coloured cap.
Application: - Wipe on/wipe off type.
- Pour Betawipe VP 04604 into applicator bottle, and immediately refit the yellow cap onto the
container.
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Page 7
Lotus Service Notes Section BQ
- Push the applicator head onto the bottle, and fit the felt pad.
- Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.
- Wipe the pad over the substrate surface using minimal pressure to wet the surface.
- Immediately wipe off the activated/cleaned surface using a clean fibre free cloth, and dis-
card.
Notes: - If the substrate is very dirty, first wipe off the surface with a clean fibre free cloth and dis-
card.
- Do not leave the caps off Betawipe containers. A milky colour indicates moisture absorption,
and the material should be discarded.
- Only decant a sufficient quantity of Betawipe for the job concerned, and never pour material
back into the container from the applicator bottle.
- Change the felt pad at regular intervals to reduce surface contamination.
BETACLEAN 3900 (A100B6008V)
Description: Degreaser and cleaning agent used for the removal of contamination from the substrate surface.
Supplied in 1 litre aluminium container with a BLACK coloured cap.
Application: - Wipe on/wipe off type.
- When substrate is very dirty, first wipe off the surface with a clean fibre-free cloth and dis-
card.
- Dampen a fibre-free cloth with Betaclean 3900, and immediately replace the black cap.
- Thoroughly clean the substrate surface with Betaclean and discard the cloth.
- Wipe off the substrate with a clean fibre-free cloth and discard.
BETAWIPE 4000 (A082B6355V)
Description: Cleaning agent which acitvates the old adhesive layer to accept new adhesive. Supplied in 250
ml aluminium containers with a BLUE cap.
Application: - The residual adhesive bead should be cut with a scalpal to leave an even thickness of ap-
proximately 1 to 2 mm.
- Dampen a fibre-free cloth with Betawipe 4000 and immediately replace the blue cap.
- Thoroughly clean the substrate surface with Betawipe and discard the cloth. Do not wipe
off.
- Allow 2 - 3 minutes flash off time before applying adhesive.
BETAPRIME 5001 (A100B6009V)
Description: Adhesion promotor used to maximise the performance of the bonding between the cleaned
and/or activated surface and the adhesive compound. Supplied in 250 ml aluminium container
with GREEN coloured cap.
Application: - Two steel balls inside the container are provided to assist mixing of the contents when shaken.
Prior to decanting Betaprime 5001, shake the container for at least 60 seconds to disperse the
solid content of the material into suspension.
- Pour the primer into the applicator bottle and immediately replace the green cap.
- Wet out the felt pan by inverting the applicator bottle and gently squeezing the sides.
- Wipe the pad over the activated/cleaned substrate surface to apply a continuous film of
primer.
- Allow to dry for a minimum of 15 minutes before applying adhesive. If adhesive is not applied
with 72 hours, wipe on/wipe off with Betawipe VP 04604.
Notes: - The appearance of the primed areas should be deep black in colour with no streaks or
voids.
To achieve this appearance, apply in smooth continuous uni-directional movement, not short
backward and forward movements. The latter technique results in inconsistent film build.
Rework any poor areas after 5 minutes (tack time), applying in the same direction.
- Replace the felt pad if moisture absorption results in hardening.
- Never return unused Betaprime back into the aluminium container.
sn_bq_cyclone.indd 7 03/03/2006 10:53:39
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