SERVICE NOTES. Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England. Tel: +44 (0) Fax: +44 (0)

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1 SERVICE NOTES Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England. Tel: +44 (0) Fax: +44 (0) Part number B132T0327D Lotus Cars Ltd.2009 Updated 30 th January 2015

2 Publication Part Number B132T0327J Lotus Cars Ltd. July This publication has been designed for use by Lotus Dealers familiar with general workshop safety procedures and practices. Take all appropriate action to guard against injury to persons or damage to property. Lotus policy is one of continuous product improvement, and the right is reserved to alter specifications at any time without notice. Whilst every care has been taken to ensure correctness of information, it is impossible to guarantee complete freedom from errors or omissions, or to accept liability arising from such errors or omissions, but nothing herein contained shall affect your statutory rights. Updated 28 th June 2011

3 CONTENTS LOTUS EVORA Section Technical Data - Engine TDT - Vehicle TDU Chassis Bodycare & Repair Body Fittings Front Suspension Rear Suspension AJ BU BV CK DJ Engine & Engine Management - Lotus supplement EJ - Toyota engine repair manual * Engine Management EMR Transmission - Manual FL - Intelligent Precision Shift (IPS) FA - Toyota transmission manuals # Wheels & Tyres Steering Brakes Engine Cooling Fuel System Electrics Circuit Diagrams - Non supercharged models before BH_ non USA Circuit Daigrams - Non supercharged models before BH_ USA Circuit Daigrams - 'S' - IPS - All VINS after BH_ All Markets Maintenance & Lubrication Air Conditioning, Heating & Ventilation Clutch Interior Trim Passive Restraint GJ HI JL KJ LN MR MR.15 MR.16 MR.16a OK PN QJ VE WF * see separate CD: T000T1516F # see separate CD: T000T1517F manual T000T1526F auto Updated 28 th June 2011 Page 3

4 VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER The Vehicle Identification Number (V.I.N.) is a unique 17-digit number used to identify the car for licencing, warranty, spares ordering and administrative purposes. The chassis frame is stamped with the V.I.N. on the crossmember beneath the driver s seat, accessible inside the cabin with the seat slid fully rearwards. Pull back a flap in the carpet to view. The number is also printed on a label stuck to the vertical face of the fuel tank bay, below the front edge of the right hand rear seat cushion or luggage shelf. Pull back a flap in the carpet to view. It is essential that the complete V.I.N. is quoted in any correspondence concerning the car, or when order ing spare parts. intro25 ohe40 2GR V.I.N. ON CHASSIS V.I.N. LABEL ENGINE NUMBER intro24 Engine Number The 6-digit engine serial number is stamped on the LH rear flange of the cylinder block, alongside the clutch housing jointface, and is viewable only from beneath after removal of the engine undertray. The number is repeated on a bar code label applied to the front face of the left hand cylinder head, which may be viewed from above using a mirror. The full V.I.N. should always be quoted with any vehicle enquiries, together with the engine number if the query is engine related. Factory records are filed against V.I.N., and specification change points are identified by V.I.N. or engine number. The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC) directives, and with those of the National Highway Traffic Safety Association (NHTSA). 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. For example 'A 1234' being 2010 model year, serial number Note that the serial number sequence re-starts at 0001 for each model year, and is shared with all other Lotus model families (e.g. Elise and Exige). Page 4

5 2009 M.Y M.Y. serial no Assembly Plant H = Hethel Manufacturer Vehicle Type Check B = Shah Model Identifier Code 122 = Evora Digit Alam 4 = Evora S C C Engine Type Restraint Model Year Chassis/Body Serial T = 2GR-FE C = Dual S.I.R. 9 = 2009 N = RHD a.c. Number + active A = 2010 P = LHD a.c. front belts B = U M.Y. serial no onwards Manufacturer Code Restraint C = Front 3pt. Dual SIR H = Front & Rear 3pt. Dual SIR U = F & R 3pt. Dual SIR. 2 x ISOFIX Model MD = Evora Model Year A = 2010 B = 2011 C = 2012 D = 2013 E = 2014 F = 2015 Market Spec. A = LHD USA B = LHD Canada C = RHD Other D = LHD Other E = Gulf States L = South Korea S C C L H Brand L = Lotus Engine T = 2GR-FE 206 kw S = 2GR-FE 257 kw Check Digit Plant H = Hethel Build Type 1 = Std. 2 = Proto. Serial Number Page 5

6 2015 M.Y. serial no onwards Manufacturer Code Restraint C = Front 3pt. Dual SIR H = Front & Rear 3pt. Dual SIR U = F & R 3pt. Dual SIR. 2 x ISOFIX Model MD = Evora Model Year F = 2015 G = 2016 H = 2017 J = 2018 K = 2019 L = 2020 Market Spec. A = LHD USA B = LHD Canada C = RHD Other D = LHD Other E = Gulf States L = Prototype N = China S C C L H Brand L = Lotus Engine T = 2GR-FE 206 kw S = 2GR-FE 257 kw Check Digit Plant H = Hethel Gearbox 1 = Manual 2 = Auto. Serial Number Updated 30 th January 2015 Page 6

7 MODEL HISTORY Evora : First deliveries commence June 2009 at '09 VIN serial number Evora S and new features for base Evora (Non-USA): December 2011 VIN character 7 = S indicates supercharged engines from 11MY VIN BH_11178 S updates only Harrop HTV1320 supercharger fitted. The exhaust system incorporates an exhaust silencer flap operated by an integrally mounted vacuum by-pass valve controlled by a solenoid. S models are fitted with twin front mounted air/oil coolers. The body styling is unchanged with the following exceptions: Door mirror covers: painted Phantom Black (Lotus code B123) as standard. Rear undertray: Additional integral underside air scoop used in conjunction with existing NACA ducts. New diffuser panel to accommodate distinctive diffuser finisher and tri-oval tailpipe silencer. Addition of the S logo to the existing Evora rear bumper badge. Brakes: Discs: Cross drilled brake discs and black painted callipers fitted to supercharged models as standard. Suspension Front lower wishbone rear bush stiffness by 10%. The bush change achieved a 12% reduction in Camber Compliance (less camber loss whilst cornering) and a 22% increase in lateral stiffness at the Tyre Contact Patch. The static geometry settings are also revised. Rear suspension: Both upper and lower wishbone bush stiffness s are increased by 10%, and the rear antiroll bar is increased by 0.5mm in diameter. The fitting of the revised components achieve a 19% reduction in Camber Compliance (less camber loss whilst cornering), a 32% increase in lateral stiffness at the Tyre Contact Patch and a 1.5% increase in rear roll stiffness. The static geometry settings are also revised. Optional Wheels: Front 19 Rear 20 Forged alloy Diamond Cut Design fitted with Bespoke Pirelli P-Zero Corsa tyres with specially formulated compound which can be identified with an LS marking on sidewall Transmission Sports Ratio Gearbox fitted as standard. Lightweight low inertia flywheel allowing the engine to climb up the rev range more freely therefore making the engine feel sportier when compared to the naturally aspirated engine. Clutch: New lighter inertia, heavy duty clutch system fitted to manage the 400Nm torque produced by the supercharged engine, consisting of a new clutch cover with revised finger ratios and an upgraded centre plate. Havoline Multigear MTF HD 75W-80 for Evora S sports ratio gearbox. All models from BH_11178 onwards A new ABS module, equipped with revised software providing: Corner Brake Control (CBC), Drag Torque Control (DTC), Electronic Stability Control (ESC), Anti-lock Braking System (ABS), Hydraulic Brake Assist (HBA), Electronic Brake Distribution (EBD), Electronic Differential Lock (EDL) and Traction Control System (TCS) The collective name for this functionality is Lotus Dynamic Performance Management (Lotus DPM). Some of these features are carried over from the existing Evora ABS system specification. Interior Heated front seats, interior tailgate release button and additional 12V aux power socket within the centre console under the HVAC controls Front intake grilles: Front bumper side intake grilles revised and blanking plates removed to allow airflow to the oil coolers but fitted to all variants. A New pedal is box fitted allowing for a revised clutch pedal ratio as well as a new clutch master cylinder to give a reduced pedal effort. Clutch line damper bolted in the fluid line at the flexi pipe by the slave cylinder. Inertia weights fitted to gearbox crank lever selector, the higher inertia created by the additional weights helps to achieve a more positive gear change. New low loss motion and low friction gearshift cables fitted with less built in tolerance than earlier D level cables to assist in a more positive gear change when shifting between all gears. See TSB 2010/17 for further information. Updated 14 th October 2011 Page 7

8 of the Evora IPS (Intelligent Precision Shift) Non USA - March 2011 Introduced from 11MY VIN BH_11746 Same vin characters as naturally aspirated Evora The Evora IPS utilises the Toyota 6 speed U660E conventional fluid filled automatic transmission and torque converter assembly. The Lotus IPS transmission system allows the driver to switch between conventional 6 speed automatic drive to manual paddle shift mode with the option of Sport mode producing quicker and more pronounced gear shifts as well as optimising shift points for performance. The same front mounted air/oil coolers used on the Evora S for engine oil cooling are now used to cool the transmission fluid with the sandwich plate/thermostat assembly now mounted remotely to the rear bulkhead. See TSB 2011/13 for further information of the 12 model year Evora range and S with IPS transmission (Supercharged with Intelligent Precision Shift). (Non USA) August VIN character 10 = C Serial number restarts at 0001, common to all. VIN character 7 indicates the engine specification. T = naturally aspirated (Manual or IPS). S = supercharged (Manual or S with IPS transmission) variants. Body styling: Unchanged with the following exceptions: Door mirror covers: All supercharged models will retain Phantom Black painted covers (Lotus code C123 Cromax Pro painting system) as standard. Exterior door handles: The chrome option has been deleted with only body coloured options available. Diffuser panel: The diffuser panel fitted to the supercharged manual vehicle is also fitted to the S with IPS transmission option to accommodate distinctive diffuser finisher and tri-oval tailpipe silencer. Badges: The S logo will also be applied to the rear bumper on the S with IPS transmission option. Front bumper: To accommodate the rationalisation of the engine and transmission oil cooler arrangements, the side intake apertures on the front bumper are revised to accept new front grilles and inlet ducts. The grilles are now bolted to the bumper with the corresponding LH/RH ducts located behind them being closed off if an oil cooler is not required on that side. Rear lamp bezels: Supercharged vehicles will have black bezels; naturally aspirated vehicles will continue to use the existing chrome versions. Seats: New leather seat colours are available dependant on interior pack option selected (Base, Executive Premium or Sports Premium). Ebony black, Ivory white, Venom red, Cognac brown, Imperial blue, Cocoa brown, Ash brown. Rear seats and relevant interior trims are coloured to match. Interior trims: A new colour (dark grey) introduced in addition to the current grey option, beige colour trim is deleted for 12 model year. Specific interior trims are coloured black to denote Supercharged variant. In Car Entertainment: For specific markets the Alpine IVA-W520R 2 DIN Mobile Media Station is replaced with the Pioneer AVIC-930BT 2 DIN head unit. Exhaust: An exhaust silencer incorporating an EP (Engine Protection) valve is now be fitted to all 12MY vehicles as standard equipment. Catalytic converters: The main/under-floor catalytic converter is deleted and replaced with a link pipe. Engine cooling: Oil cooling for both supercharged manual and IPS transmission vehicles is rationalised with the fitment of only a single larger engine oil cooler mounted ahead of RH front wheelarch. Transmission fluid cooling: Both supercharged and naturally aspirated IPS transmission vehicles is also rationalised with the fitment of a single larger transmission fluid oil cooler mounted ahead of LH front wheel arch. Brake and Power Assisted Steering pipes: fitted to the RH have been revised to allow for the fitment of an additional cooler hose and revised cooler arrangement. Manual Transmission: The standard ratio gearbox option is deleted for naturally aspirated vehicles, and the sports ratio gearbox is now fitted as standard. Brake Discs: Cross drilled brake discs fitted to all supercharged models as standard equipment. Brake Callipers: Red painted callipers replace the black coloured option and are fitted as standard to all supercharged vehicles or included in the Sports Pack option for naturally aspirated vehicles. Bare metal callipers are fitted as standard to naturally aspirated vehicles. Suspension Wishbones and rear anti-roll bars: 12 model year IPS and S with IPS transmission vehicles are Updated 14 th October 2011 Page 8

9 fitted with the S type wishbones and larger diameter rear anti-roll bar. This will also be implemented as a production running change to naturally aspirated manual vehicles at a later date. Optional Wheels: New Front 19 Rear 20 Forged wheels are available in both Gloss Black and Stealth Grey which are based on the 19 /20 alloy Diamond Cut designs launched with the Evora S but without the machined faces which are now deleted. See Technical Service Bulletin TSB 2011/25 for further details. Page 9

10 LIFTING POINTS When using a lifting jack or hoist, care must be taken to position the device only beneath the areas shown in the illustration. Each designated point uses a ribbed alloy reinforcement pad integral with the main chassis structure. Use a suitable rubber pad to provide additional protection from surface damage: A; Identified by an adjacent blue sticker. Beneath the front ends of the chassis main siderails, just behind the rear edge of the front undertray. B; Identified by an adjacent blue sticker. Beneath each end of the fuel tank bay rear crossmember, just ahead of the front edge of the engine bay undertray. If using a single jack for wheel changing purposes, a single rear lifting point (B) may be used to raise both wheels on that side of the car. With the limited vision available under these circumstances, extra care must be taken to position the jack correctly. Note that in order fully to exploit the benefits of light weight, and to maximise stowage space, the Evora has no provision for spare wheel carriage or lifting jack. A temporary puncture recovery facility is provided in the form of a tyre inflator aerosol stowed in the right hand side of the boot. B B A A ohe52 Page 10

11 UNDERTRAYS/DIFFUSER For certain service operations, it may by necessary to remove the front and rear undertrays 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. Undertray supports F Spacers Rubbing blocks D E B C D B A ohe58 Front Undertray The undertray is fixed in place to various vehicle components, to maintain a flat and level underside profile; spacers of various thicknesses are added between the undertray and its mounting points. Fixing Points A. Rear of front subframe: retained with 4 M8x20 mm screws running left to right along the rear of the front subframe and torqued to 12Nm. Each screw passes through a 4.6mm thick spacer and into a rivnuts fitted into the subframe. B. L/H & R/H suspension wishbone rear mounting: retained with 1 M8x20 mm screw on either mount and torqued to 12Nm. Each screw passes through a 3mm thick spacer into rivnuts fitted into the mounts. C. LH & RH wheelarch liner: retained with 1 push fit scrivet on either side of the front of the wheel arch liner. D. Suspension wishbone front mounting cross member: retained with 4 M8x30 mm bolts running left to right along the cross member and torqued to 12Nm the furthermost outer bolts pass through 10.6mm thick spacers and the innermost bolts pass through 13.7mm thick spacers fitted into the cross member. E. LH & RH front undertray supports: retained with 1 M6x16mm bolt on either support and are torqued to 8Nm into rivnuts fitted into the supports. The undertray supports are in turn fixed to the front subframe rails. Each bolt passes through a rubbing block positioned to the underside of the tray. The rubbing blocks protect the undertray in the event of the vehicle grounding. F. Front bumper: retained with 8 M6x16mm bolts and washers and are torqued to 8Nm. The bolts screw into captive nuts slotted into the undertray. Updated 21 st January 2014 Page 11

12 Rear Undertray Rear subframe Rear diffuser ohe57 Fixed to the rear subframe and chassis by 19 M8x20 mm screws tightened into rivnuts mounted into the subframe and chassis which are all torqued to 25Nm. The 5 bolts securing the undertray to the rear of the subframe also pass through the front of the rear diffuser, compressing the undertray between the diffuser and subframe. Page 12