Lotus Evora User Manual

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SERVICE

NOTES

Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England.

Tel: +44 (0)1953 608000 Fax: +44 (0)1953 608300 www.LotusCars.co.uk

Part number B132T0327D/09/01 © Lotus Cars Ltd.2009

Table of Contents

Service Notes1
Contents3
Vehicle Identification Number & Engine Number4
Engine Number4
Model History5
Lifting Points6
Chassis7
General Description9
Chassis Straightness Check10
Rear Subframe11
To Remove/Refit Rear Subframe11
Front Subframe12
To Remove/Refit Front Subframe12
Table of Contents14
Bodycare & Repair14
Lotus Composite Body Features16
Bodycare17
Washing17
Accident Damage Assessment18
Paintwork Polishing18
Ventilation18
Body Panel Bonding Materials19
Applicator Bottle19
Betaclean 3900 (A100B6008V)20
Betabrade F1 (A120B6043V)20
Betaclean 3300 (A120B6042V)20
Betawipe 4000 (A082B6355V)20
Betaprime 5404 (A082B6337V)21
Betaprime 1707 A+B (A111B6374V)21
Bu.121
- Roof Panel22
- Replacement of Bonded-On Panels - General22
- Plastic Panel Repair System22
- Betaseal 1701 (A082B6281F)22
Bu.322
- Windscreen Frame23
- To Replace Windscreen Frame23
Bu.423
- Body Side Panels24
- To Replace Body Side Panel24
Bu.524
- Rear Bulkhead25
- Body Fittings27
- Bv.728
- Reservoir Access Hatch29
- Tailgate29
- Access Panel Adjustment29
- Tailgate Remove/Refit29
Bu.829
- 'A' Panel Removal/Replacement30
- 'A' Panels30
- Front Bumper31
- Front Clamshell31
- Front Clamshell Removal/Replacement31
- Rear Clamshell32
- Rear Clamshell Removal/Replacement33
- Rear Bumper34
- Door Mirrors35
- Replacement of Mirror Glass and Cover35
- To Remove/Refit Rear Bumper35
- Door Shell, Beam & Hinges36
- Replacement of Mirror Assembly36
- Bv.1137
  - Check Strap37
  - Door Weatherstrip37
  - Door Weatherstrip Seals37
  - Drop Glass Waist Seal37
- Bv.1238
  - DOOR WINDOW, Guide RAILS & LIFT MECHANISM38
  - Viewed from Outboard38
- Bv.1339
  - Door Glass Adjustment39
  - Door Glass Removal39
  - Guide Rail Removal39
  - Window Lift Mechanism39
- Bv.1440
- Door Latch Mechanism40
- Bv.1541
  - Exterior Release Handle41
  - Latch Mechanism41
  - LH Door Exterior Lock41
  - Windscreen Removal/Replacement41
- Shelf Life43
- To Replace Tailgate Glass43
- Spillage of Material43
- Tailgate Glass43
- To Replace Rear Quarter Light Glass44
- Cabin Rear Window44
- Rear Quarter Light Window44
- Front Suspension46
- General Arrangement47
- Geometry & Adjustments48
- To be Revised49
- Alignment49
- Camber Adjustment50
- Cambolt Effects50
- Wishbone Pivot Bushes & Swivel Joints51
- Cambolt Illustration51
- Castor Adjustment51
- Pivot Bushes51
- Damper Pivots52
- Anti-Roll Bar52
- Steering Swivel Joints52
- Suspension Disassembly/Assembly53
- Hub Carrier53
- Damper and Spring53
- Upper Wishbone53
- Front Wheel Bearings55
- To Replace Hub Bearing Assembly55
- Rear Suspension56
- Rear Suspension Layout57
- Wishbone Pivot Bushes & Spherical Joints61
- Upper and Lower Wishbones63
- Rear Wheel Bearings64
- Engine66
- General Layout67
- Air Cleaner Element Inspection/Replacement68
- Engine Oil & Filter Change69
- Oil Filter69
- Auxiliary Drive Belt70
- Engine Removal/Replacement70
- Auxiliary Belt Replacement70
- Engine Special Tools72
- Engine Repair72
- Engine Management73
- Diagnostic Trouble Code (Dtc) List75
- Component Function79
- Diagnostic Guide83
- Camshaft Timing Control (VVT)83
- Crankshaft Position–Camshaft Position Correlation Error84
- Intake Air Flow86
- Barometric Pressure88
- Intake Air Temperature89
- Engine Coolant Temperature91
- Sensor Connections91
- Sensor Characteristics91
- Throttle Position93
- O2 Sensor (Pre Catalyst)97
- Malfunction Criteria99
- Potential Failure Modes99
- O2 Sensor (Post Catalyst)100
- Fuel Control System too Lean or Rich103
- Fuel Injection System105
- Misfire106
- Knock Control System108
- Engine Speed / Position Sensors109
- Ignition System111
- Catalyst System Efficiency112
- Evaporative Emission Control – Leak Detection System114
- Evaporative Emission Control – Purge, Open / Closed Circuit117
- Fuel Level Sensor119
- Engine Cooling Fan Control121
- Vehicle Speed Sensor122
- Idle Speed Control123
- A/C Evaporator Temperature Sensor124
- Battery Voltage125
- Cruise Control126
- Variant Code Not Programmed129
- Crank Relay130
- Fuel Pump Relay131
- VIN Not Programmed or Incompatible – ECU/PCM132
- Throttle Actuator Control Range/Performance133
- Air Conditioning System134
- Variable Intake Manifold Circuit135
- Clutch Position Sensor Circuit136
- Air Intake Control Valve Circuit138
- Coolant Recirculation Pump140
- Throttle Actuator Control Motor Circuit/Open141
- Throttle Actuator Control Motor Circuit/Low141
- Throttle Actuator Control Motor Circuit/High141
- Throttle Actuator Control System – Forced Idle142
- Throttle Actuator Control System – Forced Engine Shutdown142
- Throttle Actuator Control System – Forced Limited Power143
- Throttle Actuator Control Module Processor143
- Throttle Actuator Control Module Performance144
- Pedal Position Sensor 'D' Circuit Low144
- Pedal Position Sensor 'D' Circuit High145
- Pedal Position Sensor 'E' Circuit Low145
- Throttle Position Sensor 'A'/'B' Voltage Correlation146
- Pedal Position Sensor 'E' Circuit High146
- Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation147
- Throttle Actuator Control System – High Airflow Detected147
- A/C Refrigerant Distribution Valve148
- A/C Compressor Lock Sensor Circuit149
- Lost Communications with TCM150
- Lost Communications with VDCM150
- Lost Communications with TPMS150
- Software Incompatible with VDCM151
- Emr.2 - Can Bus Diagnostics; Lotus Techcentre152
- Transmission153
- Gearchange Mechanism155
- Gearchange Cable Adjustment156
- Gearchange Cable Replacement157
- RH Driveshaft Assembly158
- LH Driveshaft Assembly158
- Drive Shafts158
- Driveshaft Assembly Replacement159
- Driveshaft C.V. Joint And/Or Gaiter Replacement160
- Extension Shaft Support Bearing160
- Transmission Removal/Replacement162
- Transmission Overhaul162
- To Separate the Engine/Transmission Assembly162
- Wheels & Tyres163
- Tyre Pressure Monitoring System (Tpms)164
- Wheels165
- TPMS Fault Codes165
- Wheel Bolts166
- Tyres166
- Winter Tyres & Snow Chains167
- Snow Chains167
- Punctured Tyre Emergency Inflator168
- Steering169
- Column and Rack Assembly170
- Power Steering Rack Operation171
- Power Steering Schematic (RHD Shown)173
- Pas Fluid Check & Refill Procedure175
- Steering Wheel175
- Fluid Level Check175
- To Remove Steering Wheel175
- Steering Wheel Alignment176
- Steering Column Assembly177
- To Remove Steering Column Assembly177
- Track Rod Ends & Rack Gaiters178
- To Refit Steering Column Assembly178
- Front Wheel Alignment178
- Steering Rack Gaiters179
- Track Rod Ends179
- Rack & Pinion Assembly Removal/Replacement179
- To Re-Fit/Replace Steering Rack Assembly180
- PAS Pump Test Procedure180
- To Remove/Replace Steering Rack Assembly180
- Pas Pump Removal & Inspection181
- Vane Pump Mechanism182
- Braking System183
- Tell Tale Lamps186
- Brakes Tell Tale186
- Brake Fluid Check & Change186
- Brake Fluid Reservoir187
- Renewal of Brake Fluid187
- Brake Bleeding Procedure187
- Front Brake Shown188
- Parking Brake Mechanism189
- Brake Disc Thickness190
- Brake Discs190
- Parking Brake Lever190
- Parking Brake Shoes190
- Brake Callipers191
- Brake Master Cylinder191
- Rear Disc Replacement191
- Vacuum Servo Unit192
- Brakes off192
- Initial Movement192
- Pressure Balance192
- Tandem Servo Section (Brakes Off)193
- Maximum Assistance193
- Operational Check193
- Pedal Removal194
- Pedal Box194
- To Replace Brake Servo Unit194
- Electro-Hydraulic Control Unit195
- Abs Theory of Operation195
- Anti-Lock Braking196
- Sequence of Operation197
- Normal Braking197
- Pressure Isolation (Pressure Maintain)198
- Pressure Reduction199
- Pressure Increase (Re-Apply)200
- Brake Release201
- Electro-Hydraulic Unit202
- To Remove Electro-Hydraulic Unit202
- Special Tools203
- Lotus Techcentre203
- Data Link Connector (Dlc)203
- Wheel Speed Sensors203
- ‘Lotus Techcentre’ Checking Procedures204
- Trouble Codes204
- Abbreviations & Definitions205
- ECU Identification205
- Diagnostic Trouble Codes206
- Engine Cooling208
- Thermostat Closed210
- Thermostat Closed Circuit (Cold Engine)210
- Thermostat Open Circuit (Normal Running Temperature)211
- Header Tank211
- Re-Circulation Pump211
- Drain/Refill Procedure212
- Anti‑Freeze/Corrosion Inhibitor212
- Radiator Fin Cleaning212
- Radiator & Cooling Fans213
- Radiator Fans213
- Radiator Fan & Re-Circ. Pump Control214
- Radiator Feed & Return Pipes214
- Cooling Fans Control214
- Heat Soak214
- Fuel System216
- Evora Fuel System Layout217
- Fuel Requirement & Filling219
- Fuel Pressure Relief Procedure220
- Fuel Pump/Tank Sender221
- To Remove/Refit Fuel Pump Assembly221
- Fuel Tank222
- Fuel Tank Removal/Refit222
- To Remove Pump/Sender Assembly223
- To Test Fuel Pump Output223
- Charcoal Canister223
- Fuel Supply Test223
- Electrics225
- Pfk 457 Vehicle Security Alarm226
- Vehicle Security Alarm226
- Transmitter Keys226
- Disarming the Alarm/Unlocking226
- Auto Re-Arm227
- Passive Immobilisation227
- Arming the Alarm/Locking the Doors227
- Turning off the Interior Movement Sensor228
- Opening the Tailgate228
- Manual Activation of Siren228
- Transmitter Key Battery Replacement228
- Trigger Report Back and Feature Selection229
- Disconnecting the Car Battery229
- Programming Additional Transmitters229
- Quick Test230
- Location of Alarm Components230
- To Open the Doors from Outside230
- Interior Door Lock Switch230
- To Open the Doors from Inside231
- Locking the Doors Mechanically231
- Inertia Switch231
- CDL Component Location231
- Switches & Instruments - Driver's Information234
- Ignition Switch/Steering Lock234
- Bulb Check235
- High RPM Tell Tales235
- Turn Tell Tale235
- Engine Malfunction Indicator Lamp236
- Scheduled Service Tell Tale236
- Passenger Airbag off Switch236
- Rear Foglamp Tell Tale236
- Traction Control Tell Tale237
- ABS Tell Tale237
- Brake Tell Tale237
- Oil Pressure Tell Tale237
- Instruments238
- Seat Belt Tell Tale238
- Airbag Tell Tale238
- Tachometer238
- Fuel Level Display239
- Ambient Air Temperature Display239
- Time Clock239
- Information Switch239
- Tyre Pressure Units (if TPMS Is Fitted)240
- Trip Recorder240
- Ambient Temperature Units240
- Coolant Temperature Display240
- Door/Tailgate Open Display241
- Lighting Switches241
- Sidelamp Switch241
- Headlamp Switch241
- ‘Lights On’ Warning242
- Rear Fog Lamp Switch (Where Fitted)242
- Reversing Lamp, Parking Aids and Reversing Camera242
- Hazard Warning Lamps Switch242
- Steering Column Lever Switches243
- Turn Indicators/Headlamp Flash/Dipswitch243
- Wiper Functions243
- Windscreen Washer Functions243
- Interior Lighting244
- Horn244
- Passenger Airbag Defeat (PAB) Switch244
- Headlamp Powerwash244
- Lotus Traction Control245
- Sport Mode (if Fitted)245
- Component Location & Fuse Ratings247
- Main Fusebox247
- Slot Rate Circuit247
- Front Relay Blocks248
- Integrated Control Module248
- Key to ICM Diagram249
- Rear Fusebox250
- Component Location251
- Audio Equipment251
- Battery Reconnection252
- Battery Access252
- Disconnecting the Battery252
- Battery252
- Wiper Mechanism253
- Quiescent Drain253
- Battery Cables253
- Harness Routing254
- To Remove the Wiper Mechanism254
- Headlamp Assemblies255
- Xenon Headlamp Assemblies255
- Headlamp Servicing255
- Headlamp Housing Removal255
- Headlamp Units256
- HID Xenon Headlamps (if Fitted)256
- Headlamp Beam Alignment256
- Bulb Replacement256
- Rear Lamp Cluster Bulbs257
- Rear Fog and Reverse Lamps257
- Side Repeater Lamps257
- Licence Plate Lamps257
- Circuit Diagrams258
- Maintenance & Lubrication308
- Recommended Lubricants309
- 'Severe Service’ Conditions310
- Special Operating Conditions311
- Additional Servicing311
- Pre-Delivery Inspection314
- Pre-Delivery Paint Mark up - Evora316
- Licence Plate Fitment317
- Air Conditioning, Heating & Ventilation318
- Closed Circuit320
- Air Conditioning - Basic Principles320
- Heater Circuit320
- Compressor321
- Condenser321
- Receiver-Drier321
- Expansion Valve321
- Evaporator322
- Heater/A.C. Airflow Overview322
- Interior Climate Controls323
- Distribution Control323
- Face Level Vents323
- Face Level Vents & Footwells324
- Footwell Vents324
- Footwells & Windscreen324
- Re-Circulation Switch325
- Interior Fan325
- Temperature Control325
- Windscreen325
- Heated Rear Screen326
- Pollen Filter326
- Engine Bay Ventilation326
- Cooling Fans & Re-Circulation Pump326
- Refrigerant Handling327
- Refrigerant Pipework Precautions327
- Refrigerant Pipework Fixing Torques328
- Refrigerant Pipework 'O' Rings328
- Refrigerant Oil329
- Approved Oils329
- Compressor Removal329
- Oil Quantity Adjustment Prior to Compressor Refitment330
- Refitting Existing Compressor330
- Fitting New Compressor330
- Compressor Fitment331
- To Remove Condenser331
- Heater/Evaporator/Fan (Hvac) Unit332
- To Remove HVAC Unit332
- Air Distribution Unit (Adu)333
- To Remove the Air Distribution Unit333
- Refrigerant Pipes334
- Clutch335
- Clutch Pedal337
- Hydraulic Release System337
- Master Cylinder337
- To Replace the Master Cylinder337
- Slave Cylinder338
- Hydraulic Pipe338
- Inspection & Replacement339
- Clutch Assembly339
- Technical Data - Engine340
- Technical Data - Vehicle344
- Interior Trim348
- To Remove/Refit Door Trim Panel351
- Door Trim Panel Components351
- Door Sill Trim Panel351
- Trim Feature Strip & Mood Lighting351
- Lower 'A' Post Trim Panel352
- Centre Console352
- Fascia Dash Panel352
- Fascia Lower Panels353
- Main Fascia Panel353
- Steering Column Shroud353
- REAR SEAT Backrest or Bulkhead PAD354
- Rear Quarter Panels354
- Windscreen Pillar Trim Panels354
- Roof Lining355
- Airbag System356
- CAN BUS Diagnostics359
- Safety Precautions, Shipping, Storage & Disposal360
- Sensor & Diagnostic Module (SDM) & Forward Crash Sensors360
- Inflator Module360
- Vehicle Scrapping Procedures361
- Deployed Inflator Modules362
- Inspections Required after an Accident362
- Sensor & Diagnostic Module (SDM)362
- Frontal Impact Sensing and Deployment363
- Fault Display363
- To Replace SDM364
- Energy Reserve364
- Supply Voltage Range364
- Power Supply & Grounding364
- Driver Airbag Module365
- To Replace Driver's Airbag365
- Rotary Connector366
- To Replace the Rotary Connector366
- Passenger Airbag Module367
- To Replace Passenger Airbag367
- Seat Belt Pre-Tensioners368
- Device Operation368
- To Replace Front Seat Belt Assembly369
- Safety Standard369
- Transportation of Belt with Pre-Tensioner370
- Storage of Belt with Pre-Tensioner370
- Disposal of Belts with Pre-Tensioner370
- Vehicle Disposal370

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Lotus Evora Specifications

General

Brand	Lotus
Model	Evora
Category	Automobile
Language	English

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