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Lotus Evora User Manual

Lotus Evora
370 pages
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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

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Lotus Evora Specifications

General IconGeneral
BrandLotus
ModelEvora
CategoryAutomobile
LanguageEnglish

Summary

VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER

MODEL HISTORY

LIFTING POINTS

CHASSIS

General Description

Provides a general overview of the chassis construction, materials, and key structural elements.

Chassis Straightness Check

Details the procedure for checking chassis twist or distortion using tooling indents.

Rear Subframe

Describes the rear subframe's function, attachment, and removal/refitment procedure.

Front Subframe

Explains the front subframe construction, mounting, and removal/refitment process.

BODYCARE & REPAIR

General Description

Outlines the construction of body panels and their attachment methods.

Lotus Composite Body Features

Details the benefits and characteristics of composite body structures.

Bodycare

Provides guidance on maintaining the acrylic enamel paint finish and common causes of damage.

Accident Damage Assessment

Explains how to assess accident damage to composite panels and repair methods.

Body Panel Bonding Materials

Lists and describes the specified Dow Chemical bonding materials for body panels.

Replacement of Bonded-On Panels - General

Covers general procedures for replacing bonded body panels using pneumatic tools.

Roof Panel

Details the procedure for replacing the composite roof panel.

Windscreen Frame

Describes the replacement procedure for the windscreen frame assembly.

Body Side Panels

Explains the replacement of body side panels, noting the labour involved.

Rear Bulkhead

Covers the replacement of the rear bulkhead panel, including its bonding.

BODY FITTINGS

Reservoir Access Hatch

Describes the front hinged access hatch for brake/clutch reservoirs and washer filler.

Tailgate

Details the composite tailgate panel, its hinges, latch, and removal/refitment.

'A' Panels

Explains the removal and replacement of 'A' panels located below the waistline.

Front Clamshell

Details the front upper bodywork moulding, its securing, and removal/replacement.

Front Bumper

Describes the procedure for removing and refitting the front bumper.

Rear Clamshell

Covers the removal and refitment of the principal body moulding aft of the doors.

Rear Bumper

Details the removal and refitting procedure for the rear bumper moulding.

Door Mirrors

Explains the features and replacement of door mirror glass and covers.

Door Shell, Beam & Hinges

Describes the construction of the door shell, beam, and hinges.

Door Weatherstrip Seals

Covers the removal and refitting of door drop glass waist and cheater seals.

Door Window, Guide Rails & Lift Mechanism

Details the frameless door window, guide rails, and electrically operated lift mechanism.

Door Latch Mechanism

Explains the door latch mechanism, its operation, and removal/refitment.

Windscreen Removal/Replacement

Covers the procedure for removing and replacing the Evora windscreen assembly.

Tailgate Glass

Details the replacement procedure for the tailgate glass screen.

Cabin Rear Window

Describes the double glazed cabin rear window and its bonding.

Rear Quarter Light Window

Covers the replacement procedure for the rear quarter light window glass.

FRONT SUSPENSION

General Description

Provides an overview of the independent front suspension components and design.

Geometry & Adjustments

Details wheel alignment, camber, castor, and other geometry adjustments.

Wishbone Pivot Bushes & Swivel Joints

Describes the construction and replacement of wishbone pivot bushes and swivel joints.

Anti-Roll Bar

Explains the mounting, function, and components of the tubular steel anti-roll bar.

Suspension Disassembly/Assembly

Provides a step-by-step guide for disassembling and assembling the front suspension.

Front Wheel Bearings

Details the hub bearing unit, its replacement, and associated torque settings.

REAR SUSPENSION

General Description

Provides an overview of the independent rear suspension components and design.

Geometry & Adjustments

Details wheel alignment, camber, and thrust angle adjustments for the rear suspension.

Wishbone Pivot Bushes & Spherical Joints

Describes the construction and replacement of rear wishbone pivot bushes and spherical joints.

Anti-Roll Bar

Explains the mounting and function of the tubular steel rear anti-roll bar.

Suspension Disassembly/Assembly

Provides a step-by-step guide for disassembling and assembling the rear suspension.

Rear Wheel Bearings

Details the rear hub bearing unit, its replacement, and associated torque settings.

ENGINE

Introduction

Provides a general description of the engine's layout, type, and terminology.

Air Cleaner Element Inspection/Replacement

Details the procedure for inspecting and replacing the air cleaner element.

Engine Oil & Filter Change

Provides instructions for changing the engine oil and filter, including safety warnings.

Auxiliary Drive Belt

Describes the auxiliary drive belt, its inspection, and replacement procedure.

Engine Removal/Replacement

Outlines the procedure for removing and replacing the complete engine and transmission unit.

Engine Special Tools

Lists special tools required for engine repair and handling.

Engine Repair (CD T000T1506)

Directs users to CD for detailed engine repair information and links.

ENGINE MANAGEMENT

Diagnostic Trouble Code List

Lists diagnostic trouble codes (DTCs) with fault descriptions and corresponding page numbers.

CAN Bus Diagnostics; Lotus TechCentre

Explains CAN bus diagnostics and the use of the Lotus TechCentre tool.

TRANSMISSION

Introduction

Provides an overview of the 6-speed manual transaxle assembly and its features.

Gearchange Mechanism

Details the gearchange lever, cables, and the mechanism for engaging gears including reverse.

Lubrication

Specifies inspection intervals and procedures for transmission oil renewal.

Driveshafts

Describes the driveshaft assemblies, CV joints, and their maintenance.

Transmission Removal/Replacement

Outlines the procedure for separating and refitting the transmission from the engine.

Transmission Overhaul

Refers to Lotus CD for detailed transmission repair and overhaul procedures.

WHEELS & TYRES

General Description

Details the factory-fitted roadwheels and tyres, including size and tread pattern.

Tyre Pressure Monitoring System (TPMS) - Where fitted

Explains the TPMS operation, alerts, and fault detection.

Wheels

Describes the standard and optional wheels, including specifications and fixing details.

Wheel Bolts

Details the special design of wheel bolts, torque specifications, and key coding.

Tyres

Describes the Pirelli P-Zero tyres, their characteristics, and winter tyre recommendations.

Winter Tyres & Snow Chains

Provides recommendations for winter tyres and the use of snow chains.

Punctured Tyre Emergency Inflator (If fitted)

Details the operation and use of the temporary tyre sealing facility.

STEERING

General Description

Provides an overview of the power assisted steering system components and layout.

Power Steering Rack Operation

Explains the operation of the steering rack assembly and its hydraulic valve body.

PAS Fluid Check & Refill Procedure

Details the procedure for checking and refilling the power steering fluid.

Steering Wheel

Describes the steering wheel features and the procedure for its removal.

Steering Column Assembly

Details the construction of the steering column assembly and its removal procedure.

Track Rod Ends & Rack Gaiters

Covers front wheel alignment, track rod ends, and steering rack gaiter inspection/replacement.

Rack & Pinion Assembly Removal/Replacement

Provides the procedure for removing and replacing the steering rack assembly.

PAS Pump & Testing Procedure

Details the procedure for testing the PAS pump and its operation.

BRAKING SYSTEM

General Description

Provides an overview of the braking system, calipers, discs, and ABS integration.

Tell Tale Lamps

Explains the function of the brake system warning tell tale lamps.

Brake Fluid Check & Change

Details the procedure for checking, refilling, and renewing brake fluid.

Brake Pad Replacement (front and rear)

Covers the procedure for removing and replacing brake pads.

Parking Brake Mechanism

Describes the parking brake lever, cables, and adjustment procedure.

Brake Discs

Details brake disc specifications, condition checks, and replacement procedures.

Brake Callipers

Describes the brake calipers, their specifications, and overhaul information.

Brake Master Cylinder

Covers the brake master cylinder, its function, and removal/replacement procedure.

Vacuum Servo Unit

Explains the vacuum brake servo operation, checks, and replacement procedure.

Pedal Box

Details the construction of the pedal box and the removal of pedals.

ABS Theory of Operation

Explains the principles of the Bosch antilock brake system and its modes of operation.

ABS Electro-Hydraulic Unit

Describes the electro-hydraulic control unit, its connections, and removal/refitting.

Wheel Speed Sensors

Details the vehicle speed sensor ring and sensor, and their function.

Data Link Connector (DLC)

Explains the function and location of the Data Link Connector for diagnostics.

Special Tools

Lists special tools required for system diagnostics and calibration.

Lotus TechCentre Checking Procedures

Outlines procedures for using the Lotus TechCentre for checking system faults.

ENGINE COOLING

General Description

Describes the engine liquid cooling system components and plumbing.

Maintenance

Provides guidelines for checking coolant levels and anti-freeze/corrosion inhibitor.

Drain/Refill Procedure

Details the procedure for draining and refilling the cooling system.

Radiator & Cooling Fan

Covers the mounting, removal, and replacement of the radiator and cooling fans.

Radiator Fan & Re-circ. Pump Control

Explains the control logic for cooling fans and the re-circulation pump.

Radiator Feed & Return Pipes

Describes the routing and replacement of radiator feed and return pipes.

FUEL SYSTEM

General Description

Provides an overview of the fuel tank, pump, venting, and emission control systems.

Fuel Requirement & Filling

Details the correct fuel types, filling procedures, and warnings.

Precautions

Outlines safety precautions for servicing the fuel supply circuit.

Fuel Pump/Sender Assembly

Describes the removal and refitting of the fuel pump/sender assembly.

Fuel Tank

Details the fuel tank mounting and the procedure for its removal/refitment.

Fuel Supply Test

Explains how to test the fuel pump output and fuel pressure.

Charcoal Canister

Describes the function and location of the charcoal canister and its control system.

ELECTRICS

PFK 457 Vehicle Security Alarm

Details the features of the standard immobiliser/alarm system.

Central Door Locking

Explains the operation of the central door locking system and its features.

Electric Windows

Describes the electric window lift mechanism and operation.

Door Mirrors

Covers the features, adjustment, and heating of the rear view mirrors.

Switches & Instruments - Driver's Information

Details the ignition switch, tell tale lamps, instruments, and driver controls.

Component Location & Fuse Ratings

Lists the location of fuses and relays and their corresponding circuits.

Audio Equipment

Describes the features of the audio system and speaker locations.

Battery, Battery Cables & Earthing Points

Covers battery access, disconnection, reconnection, and charging procedures.

Wiper Mechanism

Details the windscreen wiper mechanism and its removal/refitting.

Harness Routing

Illustrates the routing of the main and other electrical harnesses.

Headlamp Assemblies

Describes Xenon and Halogen headlamp assemblies and their servicing.

Bulb Replacement

Provides procedures for replacing headlamp units and other bulbs.

Instrument Panel

Details the removal and refitting procedure for the instrument panel.

Circuit Diagrams

Provides a list of circuit diagrams and their corresponding sheet and page numbers.

MAINTENANCE & LUBRICATION

Recommended Lubricants

Specifies recommended lubricants for engine, transmission, brakes, clutch, and PAS.

Maintenance Schedule

Details the required maintenance schedule for normal and severe service conditions.

Pre-Delivery Inspection

Provides a checklist for pre-delivery inspection of vehicle systems and components.

Pre-Delivery Paint Mark Up - EVORA

Illustrates paint defect codes and their application for pre-delivery inspection.

Licence Plate Fitment

Describes the procedure for fitting front and rear licence plates.

AIR CONDITIONING, HEATING & VENTILATION

General Description

Describes the HVAC unit, heater circuit, and basic AC principles.

Heater/A.C. Airflow Overview

Details the airflow paths and controls within the HVAC unit.

Cooling Fans & Re-circulation Pump

Explains the control of cooling fans and the re-circulation pump based on temperature.

Refrigerant Handling

Provides essential precautions for handling refrigerant HFC R134a.

Refrigerant Pipework Precautions

Outlines necessary precautions before disconnecting refrigerant pipework.

Refrigerant Oil

Specifies the type of refrigerant oil and handling precautions.

Compressor

Describes the AC compressor, its operation, and removal/refitment.

Condenser

Details the condenser's construction, mounting, and removal procedure.

Receiver-Drier

Explains the function and replacement of the receiver-drier unit.

Heater/Evaporator/Fan (HVAC) Unit

Covers the removal and refitting procedure for the HVAC unit.

Air Distribution Unit (ADU)

Details the removal procedure for the air distribution unit.

Refrigerant Pipes

Describes the refrigerant pipes and their unlikely necessity for replacement.

CLUTCH

General Description

Describes the clutch assembly, flywheel, pressure plate, and release mechanism.

Clutch Pedal

Details the construction of the clutch pedal and its associated components.

Hydraulic Release System

Explains the master and slave cylinders, and hydraulic system bleeding procedures.

Clutch Assembly

Covers the inspection and replacement of the clutch assembly components.

TECHNICAL DATA - ENGINE

General

Provides general engine specifications, configuration, and capacities.

Cylinder Block

Details the material, configuration, bore, and deck face flatness of the cylinder block.

Cylinder Head

Provides specifications for the cylinder head, including flatness and valve guide details.

Valves & Springs

Lists specifications for valve stem diameter, overall length, and seat contact width.

Camshafts

Provides specifications for camshaft endfloat and maximum oil clearance.

Pistons

Lists specifications for piston diameter and bore oil clearance.

Crankshaft

Provides specifications for crankshaft main journal diameter and runout.

Oil Pump

Lists specifications for oil pump rotor tip and annulus clearances, and hot oil pressure.

Coolant Thermostat

Specifies the valve opening temperature and lift for the coolant thermostat.

TECHNICAL DATA - VEHICLE

Dimensions

Lists overall vehicle dimensions, wheelbase, track, and overhangs.

Capacities

Specifies capacities for engine oil, transmission oil, brake fluid, coolant, and refrigerant.

Wheels & Tyres

Details tyre types, sizes, pressures, and wheel specifications.

Front Suspension

Provides technical data for the front suspension geometry and components.

Rear Suspension

Provides technical data for the rear suspension geometry and components.

Electrical

Lists specifications for light bulbs, system voltage, alternator, and battery.

Transmission

Provides transmission designation, differential type, and gear ratio table.

Clutch

Details clutch type, friction plate specifications, and clamp load.

Brakes

Provides specifications for brake discs, calipers, master cylinder, and parking brake.

Steering

Details steering type, and turns lock to lock.

Fuel Consumption

Lists fuel consumption figures for urban, extra urban, and combined driving.

INTERIOR TRIM

General Description

Describes the interior trim panels manufactured by SRIM, Polyurethane Foam, and RTC moulding.

Door Trim Panel

Details the door trim panel and its securing methods.

Door Trim Panel Components

Describes components related to the door trim panel, like escutcheons and handles.

Door Sill Trim Panel

Explains the securing of the door sill trim panel.

Lower 'A' Post Trim Panel

Details the removal of the lower 'A' post trim panel.

Centre Console

Provides the procedure for removing the centre console.

Fascia Dash Panel

Details the removal procedure for the fascia dash panel.

Fascia Lower Panels

Explains the removal of the left, right, and centre fascia lower panels.

Main Fascia Panel

Details the removal procedure for the main fascia panel.

Steering Column Shroud

Describes the removal of the steering column shroud.

Windscreen Pillar Trim Panels

Details the retention method for windscreen pillar trim panels.

Rear Quarter Panels

Covers the removal procedure for the rear quarter panels.

Rear Seat Backrest or Bulkhead Pad

Details the removal of the rear seat backrest or bulkhead pad.

Rear Window Surround

Explains the securing method for the rear window surround.

Roof Lining

Details the removal procedure for the roof lining panel.

AIRBAG SYSTEM

General Description

Describes the SRS system, dual stage airbags, and seat belt pre-tensioners.

Airbag Tell Tale

Explains the airbag tell tale lamp function and fault indications.

Data Link Connector (DLC)

Details the Data Link Connector for communication with SRS modules.

Trouble Codes

Explains the types of trouble codes stored by the SDM (Present and History).

Lotus TechCentre

Describes the use of the Lotus TechCentre for CAN bus diagnostics.

Safety Precautions, Shipping, Storage & Disposal

Outlines safety precautions for handling, storing, and disposing of airbag modules.

Theory of Operation

Explains the key components and functionality of the Supplementary Restraint System (SRS).

Sensor & Diagnostic Module (SDM)

Details the SDM mounting, replacement procedure, and torque settings.

Driver Airbag Module

Covers the driver's airbag module housing, replacement, and safety precautions.

Rotary Connector

Explains the function and replacement of the rotary connector.

Passenger Airbag Module

Details the passenger airbag module mounting and replacement procedure.

Seat Belt Pre-tensioners

Describes the operation, replacement, and safety standards for seat belt pre-tensioners.

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