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Lotus Evora User Manual
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Page 1
Lotus Service Notes
Section BU
BODYCARE & REP
AIR
SECTION BU
Sub-Section Page
General Description
BU.1
3
Lotus Composite Body Features
BU.2
3
Bodycare
BU.3
4
Accident Damage
Assessment
BU.4
5
Body Panel Bonding Materials
BU.5
6
Replacement of Bonded-On Panels - General
BU.6
9
Roof Panel
BU.7
9
Windscreen Frame
BU.8
10
Body Side Panels
BU.9
1
1
Rear Bulkhead
BU.10
12
13
15
Table of Contents
Service Notes
1
Contents
3
Vehicle Identification Number & Engine Number
4
Engine Number
4
Model History
5
Lifting Points
6
Chassis
7
General Description
9
Chassis Straightness Check
10
Rear Subframe
11
To Remove/Refit Rear Subframe
11
Front Subframe
12
To Remove/Refit Front Subframe
12
Table of Contents
14
Bodycare & Repair
14
Lotus Composite Body Features
16
Bodycare
17
Washing
17
Accident Damage Assessment
18
Paintwork Polishing
18
Ventilation
18
Body Panel Bonding Materials
19
Applicator Bottle
19
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.1
21
Roof Panel
22
Replacement of Bonded-On Panels - General
22
Plastic Panel Repair System
22
Betaseal 1701 (A082B6281F)
22
Bu.3
22
Windscreen Frame
23
To Replace Windscreen Frame
23
Bu.4
23
Body Side Panels
24
To Replace Body Side Panel
24
Bu.5
24
Rear Bulkhead
25
Body Fittings
27
Bv.7
28
Reservoir Access Hatch
29
Tailgate
29
Access Panel Adjustment
29
Tailgate Remove/Refit
29
Bu.8
29
'A' Panel Removal/Replacement
30
'A' Panels
30
Front Bumper
31
Front Clamshell
31
Front Clamshell Removal/Replacement
31
Rear Clamshell
32
Rear Clamshell Removal/Replacement
33
Rear Bumper
34
Door Mirrors
35
Replacement of Mirror Glass and Cover
35
To Remove/Refit Rear Bumper
35
Door Shell, Beam & Hinges
36
Replacement of Mirror Assembly
36
Bv.11
37
Check Strap
37
Door Weatherstrip
37
Door Weatherstrip Seals
37
Drop Glass Waist Seal
37
Bv.12
38
DOOR WINDOW, Guide RAILS & LIFT MECHANISM
38
Viewed from Outboard
38
Bv.13
39
Door Glass Adjustment
39
Door Glass Removal
39
Guide Rail Removal
39
Window Lift Mechanism
39
Bv.14
40
Door Latch Mechanism
40
Bv.15
41
Exterior Release Handle
41
Latch Mechanism
41
LH Door Exterior Lock
41
Windscreen Removal/Replacement
41
Shelf Life
43
To Replace Tailgate Glass
43
Spillage of Material
43
Tailgate Glass
43
To Replace Rear Quarter Light Glass
44
Cabin Rear Window
44
Rear Quarter Light Window
44
Front Suspension
46
General Arrangement
47
Geometry & Adjustments
48
To be Revised
49
Alignment
49
Camber Adjustment
50
Cambolt Effects
50
Wishbone Pivot Bushes & Swivel Joints
51
Cambolt Illustration
51
Castor Adjustment
51
Pivot Bushes
51
Damper Pivots
52
Anti-Roll Bar
52
Steering Swivel Joints
52
Suspension Disassembly/Assembly
53
Hub Carrier
53
Damper and Spring
53
Upper Wishbone
53
Front Wheel Bearings
55
To Replace Hub Bearing Assembly
55
Rear Suspension
56
Rear Suspension Layout
57
Wishbone Pivot Bushes & Spherical Joints
61
Upper and Lower Wishbones
63
Rear Wheel Bearings
64
Engine
66
General Layout
67
Air Cleaner Element Inspection/Replacement
68
Engine Oil & Filter Change
69
Oil Filter
69
Auxiliary Drive Belt
70
Engine Removal/Replacement
70
Auxiliary Belt Replacement
70
Engine Special Tools
72
Engine Repair
72
Engine Management
73
Diagnostic Trouble Code (Dtc) List
75
Component Function
79
Diagnostic Guide
83
Camshaft Timing Control (VVT)
83
Crankshaft Position–Camshaft Position Correlation Error
84
Intake Air Flow
86
Barometric Pressure
88
Intake Air Temperature
89
Engine Coolant Temperature
91
Sensor Connections
91
Sensor Characteristics
91
Throttle Position
93
O2 Sensor (Pre Catalyst)
97
Malfunction Criteria
99
Potential Failure Modes
99
O2 Sensor (Post Catalyst)
100
Fuel Control System too Lean or Rich
103
Fuel Injection System
105
Misfire
106
Knock Control System
108
Engine Speed / Position Sensors
109
Ignition System
111
Catalyst System Efficiency
112
Evaporative Emission Control – Leak Detection System
114
Evaporative Emission Control – Purge, Open / Closed Circuit
117
Fuel Level Sensor
119
Engine Cooling Fan Control
121
Vehicle Speed Sensor
122
Idle Speed Control
123
A/C Evaporator Temperature Sensor
124
Battery Voltage
125
Cruise Control
126
Variant Code Not Programmed
129
Crank Relay
130
Fuel Pump Relay
131
VIN Not Programmed or Incompatible – ECU/PCM
132
Throttle Actuator Control Range/Performance
133
Air Conditioning System
134
Variable Intake Manifold Circuit
135
Clutch Position Sensor Circuit
136
Air Intake Control Valve Circuit
138
Coolant Recirculation Pump
140
Throttle Actuator Control Motor Circuit/Open
141
Throttle Actuator Control Motor Circuit/Low
141
Throttle Actuator Control Motor Circuit/High
141
Throttle Actuator Control System – Forced Idle
142
Throttle Actuator Control System – Forced Engine Shutdown
142
Throttle Actuator Control System – Forced Limited Power
143
Throttle Actuator Control Module Processor
143
Throttle Actuator Control Module Performance
144
Pedal Position Sensor 'D' Circuit Low
144
Pedal Position Sensor 'D' Circuit High
145
Pedal Position Sensor 'E' Circuit Low
145
Throttle Position Sensor 'A'/'B' Voltage Correlation
146
Pedal Position Sensor 'E' Circuit High
146
Pedal Position Sensor/Switch 'D'/'E' Voltage Correlation
147
Throttle Actuator Control System – High Airflow Detected
147
A/C Refrigerant Distribution Valve
148
A/C Compressor Lock Sensor Circuit
149
Lost Communications with TCM
150
Lost Communications with VDCM
150
Lost Communications with TPMS
150
Software Incompatible with VDCM
151
Emr.2 - Can Bus Diagnostics; Lotus Techcentre
152
Transmission
153
Gearchange Mechanism
155
Gearchange Cable Adjustment
156
Gearchange Cable Replacement
157
RH Driveshaft Assembly
158
LH Driveshaft Assembly
158
Drive Shafts
158
Driveshaft Assembly Replacement
159
Driveshaft C.V. Joint And/Or Gaiter Replacement
160
Extension Shaft Support Bearing
160
Transmission Removal/Replacement
162
Transmission Overhaul
162
To Separate the Engine/Transmission Assembly
162
Wheels & Tyres
163
Tyre Pressure Monitoring System (Tpms)
164
Wheels
165
TPMS Fault Codes
165
Wheel Bolts
166
Tyres
166
Winter Tyres & Snow Chains
167
Snow Chains
167
Punctured Tyre Emergency Inflator
168
Steering
169
Column and Rack Assembly
170
Power Steering Rack Operation
171
Power Steering Schematic (RHD Shown)
173
Pas Fluid Check & Refill Procedure
175
Steering Wheel
175
Fluid Level Check
175
To Remove Steering Wheel
175
Steering Wheel Alignment
176
Steering Column Assembly
177
To Remove Steering Column Assembly
177
Track Rod Ends & Rack Gaiters
178
To Refit Steering Column Assembly
178
Front Wheel Alignment
178
Steering Rack Gaiters
179
Track Rod Ends
179
Rack & Pinion Assembly Removal/Replacement
179
To Re-Fit/Replace Steering Rack Assembly
180
PAS Pump Test Procedure
180
To Remove/Replace Steering Rack Assembly
180
Pas Pump Removal & Inspection
181
Vane Pump Mechanism
182
Braking System
183
Tell Tale Lamps
186
Brakes Tell Tale
186
Brake Fluid Check & Change
186
Brake Fluid Reservoir
187
Renewal of Brake Fluid
187
Brake Bleeding Procedure
187
Front Brake Shown
188
Parking Brake Mechanism
189
Brake Disc Thickness
190
Brake Discs
190
Parking Brake Lever
190
Parking Brake Shoes
190
Brake Callipers
191
Brake Master Cylinder
191
Rear Disc Replacement
191
Vacuum Servo Unit
192
Brakes off
192
Initial Movement
192
Pressure Balance
192
Tandem Servo Section (Brakes Off)
193
Maximum Assistance
193
Operational Check
193
Pedal Removal
194
Pedal Box
194
To Replace Brake Servo Unit
194
Electro-Hydraulic Control Unit
195
Abs Theory of Operation
195
Anti-Lock Braking
196
Sequence of Operation
197
Normal Braking
197
Pressure Isolation (Pressure Maintain)
198
Pressure Reduction
199
Pressure Increase (Re-Apply)
200
Brake Release
201
Electro-Hydraulic Unit
202
To Remove Electro-Hydraulic Unit
202
Special Tools
203
Lotus Techcentre
203
Data Link Connector (Dlc)
203
Wheel Speed Sensors
203
‘Lotus Techcentre’ Checking Procedures
204
Trouble Codes
204
Abbreviations & Definitions
205
ECU Identification
205
Diagnostic Trouble Codes
206
Engine Cooling
208
Thermostat Closed
210
Thermostat Closed Circuit (Cold Engine)
210
Thermostat Open Circuit (Normal Running Temperature)
211
Header Tank
211
Re-Circulation Pump
211
Drain/Refill Procedure
212
Anti‑Freeze/Corrosion Inhibitor
212
Radiator Fin Cleaning
212
Radiator & Cooling Fans
213
Radiator Fans
213
Radiator Fan & Re-Circ. Pump Control
214
Radiator Feed & Return Pipes
214
Cooling Fans Control
214
Heat Soak
214
Fuel System
216
Evora Fuel System Layout
217
Fuel Requirement & Filling
219
Fuel Pressure Relief Procedure
220
Fuel Pump/Tank Sender
221
To Remove/Refit Fuel Pump Assembly
221
Fuel Tank
222
Fuel Tank Removal/Refit
222
To Remove Pump/Sender Assembly
223
To Test Fuel Pump Output
223
Charcoal Canister
223
Fuel Supply Test
223
Electrics
225
Pfk 457 Vehicle Security Alarm
226
Vehicle Security Alarm
226
Transmitter Keys
226
Disarming the Alarm/Unlocking
226
Auto Re-Arm
227
Passive Immobilisation
227
Arming the Alarm/Locking the Doors
227
Turning off the Interior Movement Sensor
228
Opening the Tailgate
228
Manual Activation of Siren
228
Transmitter Key Battery Replacement
228
Trigger Report Back and Feature Selection
229
Disconnecting the Car Battery
229
Programming Additional Transmitters
229
Quick Test
230
Location of Alarm Components
230
To Open the Doors from Outside
230
Interior Door Lock Switch
230
To Open the Doors from Inside
231
Locking the Doors Mechanically
231
Inertia Switch
231
CDL Component Location
231
Switches & Instruments - Driver's Information
234
Ignition Switch/Steering Lock
234
Bulb Check
235
High RPM Tell Tales
235
Turn Tell Tale
235
Engine Malfunction Indicator Lamp
236
Scheduled Service Tell Tale
236
Passenger Airbag off Switch
236
Rear Foglamp Tell Tale
236
Traction Control Tell Tale
237
ABS Tell Tale
237
Brake Tell Tale
237
Oil Pressure Tell Tale
237
Instruments
238
Seat Belt Tell Tale
238
Airbag Tell Tale
238
Tachometer
238
Fuel Level Display
239
Ambient Air Temperature Display
239
Time Clock
239
Information Switch
239
Tyre Pressure Units (if TPMS Is Fitted)
240
Trip Recorder
240
Ambient Temperature Units
240
Coolant Temperature Display
240
Door/Tailgate Open Display
241
Lighting Switches
241
Sidelamp Switch
241
Headlamp Switch
241
‘Lights On’ Warning
242
Rear Fog Lamp Switch (Where Fitted)
242
Reversing Lamp, Parking Aids and Reversing Camera
242
Hazard Warning Lamps Switch
242
Steering Column Lever Switches
243
Turn Indicators/Headlamp Flash/Dipswitch
243
Wiper Functions
243
Windscreen Washer Functions
243
Interior Lighting
244
Horn
244
Passenger Airbag Defeat (PAB) Switch
244
Headlamp Powerwash
244
Lotus Traction Control
245
Sport Mode (if Fitted)
245
Component Location & Fuse Ratings
247
Main Fusebox
247
Slot Rate Circuit
247
Front Relay Blocks
248
Integrated Control Module
248
Key to ICM Diagram
249
Rear Fusebox
250
Component Location
251
Audio Equipment
251
Battery Reconnection
252
Battery Access
252
Disconnecting the Battery
252
Battery
252
Wiper Mechanism
253
Quiescent Drain
253
Battery Cables
253
Harness Routing
254
To Remove the Wiper Mechanism
254
Headlamp Assemblies
255
Xenon Headlamp Assemblies
255
Headlamp Servicing
255
Headlamp Housing Removal
255
Headlamp Units
256
HID Xenon Headlamps (if Fitted)
256
Headlamp Beam Alignment
256
Bulb Replacement
256
Rear Lamp Cluster Bulbs
257
Rear Fog and Reverse Lamps
257
Side Repeater Lamps
257
Licence Plate Lamps
257
Circuit Diagrams
258
Maintenance & Lubrication
308
Recommended Lubricants
309
'Severe Service’ Conditions
310
Special Operating Conditions
311
Additional Servicing
311
Pre-Delivery Inspection
314
Pre-Delivery Paint Mark up - Evora
316
Licence Plate Fitment
317
Air Conditioning, Heating & Ventilation
318
Closed Circuit
320
Air Conditioning - Basic Principles
320
Heater Circuit
320
Compressor
321
Condenser
321
Receiver-Drier
321
Expansion Valve
321
Evaporator
322
Heater/A.C. Airflow Overview
322
Interior Climate Controls
323
Distribution Control
323
Face Level Vents
323
Face Level Vents & Footwells
324
Footwell Vents
324
Footwells & Windscreen
324
Re-Circulation Switch
325
Interior Fan
325
Temperature Control
325
Windscreen
325
Heated Rear Screen
326
Pollen Filter
326
Engine Bay Ventilation
326
Cooling Fans & Re-Circulation Pump
326
Refrigerant Handling
327
Refrigerant Pipework Precautions
327
Refrigerant Pipework Fixing Torques
328
Refrigerant Pipework 'O' Rings
328
Refrigerant Oil
329
Approved Oils
329
Compressor Removal
329
Oil Quantity Adjustment Prior to Compressor Refitment
330
Refitting Existing Compressor
330
Fitting New Compressor
330
Compressor Fitment
331
To Remove Condenser
331
Heater/Evaporator/Fan (Hvac) Unit
332
To Remove HVAC Unit
332
Air Distribution Unit (Adu)
333
To Remove the Air Distribution Unit
333
Refrigerant Pipes
334
Clutch
335
Clutch Pedal
337
Hydraulic Release System
337
Master Cylinder
337
To Replace the Master Cylinder
337
Slave Cylinder
338
Hydraulic Pipe
338
Inspection & Replacement
339
Clutch Assembly
339
Technical Data - Engine
340
Technical Data - Vehicle
344
Interior Trim
348
To Remove/Refit Door Trim Panel
351
Door Trim Panel Components
351
Door Sill Trim Panel
351
Trim Feature Strip & Mood Lighting
351
Lower 'A' Post Trim Panel
352
Centre Console
352
Fascia Dash Panel
352
Fascia Lower Panels
353
Main Fascia Panel
353
Steering Column Shroud
353
REAR SEAT Backrest or Bulkhead PAD
354
Rear Quarter Panels
354
Windscreen Pillar Trim Panels
354
Roof Lining
355
Airbag System
356
CAN BUS Diagnostics
359
Safety Precautions, Shipping, Storage & Disposal
360
Sensor & Diagnostic Module (SDM) & Forward Crash Sensors
360
Inflator Module
360
Vehicle Scrapping Procedures
361
Deployed Inflator Modules
362
Inspections Required after an Accident
362
Sensor & Diagnostic Module (SDM)
362
Frontal Impact Sensing and Deployment
363
Fault Display
363
To Replace SDM
364
Energy Reserve
364
Supply Voltage Range
364
Power Supply & Grounding
364
Driver Airbag Module
365
To Replace Driver's Airbag
365
Rotary Connector
366
To Replace the Rotary Connector
366
Passenger Airbag Module
367
To Replace Passenger Airbag
367
Seat Belt Pre-Tensioners
368
Device Operation
368
To Replace Front Seat Belt Assembly
369
Safety Standard
369
Transportation of Belt with Pre-Tensioner
370
Storage of Belt with Pre-Tensioner
370
Disposal of Belts with Pre-Tensioner
370
Vehicle Disposal
370
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Lotus Evora Specifications
General
Brand
Lotus
Model
Evora
Category
Automobile
Language
English
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