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Lotus Service Notes Section WF
The belt pre-tensioning mechanism is designed to operate only once, such that both front belt assemblies
should be renewed after airbag/seat belt pre-tensioner deployment. Activation of the pyrotechnic mechanism
is indicated by the belt reel being locked, and allowing neither extraction nor retraction of the belt.
To replace front seat belt assembly
Each front seat belt reel assembly is secured to the seat belt mounting frame/roof hoop by a single bolt,
with an orientation tag on the belt reel engaging with a slot in the mounting plate.
WARNING: Before removing or refitting a pyrotechnic seat belt assembly, the ignition key should be
withdrawn, and the battery leads disconnected from both positive and negative terminals, and isolated
to ensure that accidental contact cannot occur.
1. Remove the rear quarter trim panel (refer to sub-section VE.11).
2. Unplug the vehicle harness from the belt tensioner initiator, and release the belt reel assembly retaining
bolt.
3. Refit in reverse order to removal, tightening the belt reel securing bolt to 33 Nm.
4. When all service work is complete, check that the airbag tell tale lights for a few seconds with ignition, and
then goes out.
Safety Standard
The pre-tensioning function is energised via pyrotechnic materials, therefore manipulation, handling and
storage MUST be performed to the specified procedures as described to avoid any occurrence of injury to the
operator or damage to the pre-tensioning unit.
In normal conditions, the pre-tensioner assembly can only be activated through the action of the electric
ignition control during impact. During the activation phase of the pyrotechnic charge, small gas quantities are
developed. The main constituent of the gases is Nitrogen:
Note! This gas is not toxic.
The pre-tensioner assemblies must be protected against exposure;
- To temperatures over 90°C (195°F) at contact with surfaces
- 90°C during 106 hrs.
- From sparks and naked flames.
WARNING: If exposed to temperatures in excess of 140°C, self-ignition of the pyrotechnic charge of
the gas generator may occur. Exposure to temperatures in excess of 165°C, self-ignition of the pyro-
technic charge will occur.
Also, if exposed to temperatures between 90°C (285°F) and 165°C (330°F), deterioration of the pyro-
technic charge ignition is possible. The consequences of this could be failure to activate at prescribed levels.
The pre-tensioner must be protected against stresses, shocks and dropping. Pre-tensioners that have been
subjected to such treatment must be discarded and returned to the supplier with accompanying paperwork
describing the reasons for return.
Never store pre-tensioner assemblies with other flammable or combustible materials. Gas generators
MUST be prevented from coming into contact with acid, water, grease and heavy metals: Contact with these
substances may cause toxic or dangerous gases, or explosive mixtures.
Any residual fuel of the gas generator, not burned during ignition, is slightly flammable. The unit, therefore,
must never be disassembled, damaged or the parts manipulated. Any advertising or demonstrations of the
pre-tensioner assembly should only be carried out using inert pre-tensioners (without the pyrotechnic charge).
The base of the pre-tensioner must be painted green, with visible and indelible wording, stating ‘Inert Assem-
bly’. It must incorporate the KSS logo, signed with indelible ink by the person responsible for the supply of the
product.
WARNING: Never disassemble the pre-tensioner or any of it’s components!
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