How to use these pages:
1- This page is the main index page.
2- You find a link to each chapter above.
3- In each chapter you will find an index of the chapter and a link to a Overview
page and a Print page.
4- The Overview page is the whole chapter with small (5-9 K) images of each
page of the chapter. You can click on each image to get the original, 300 dpi
image of the page.
5- The Print page is also the whole chapter, but with original, 300 dpi images
(50 - 150 K per page) of each page. Be aware that some chapter are big (chapter
BJ is 7,9 MB big) and loading and printing is SLOW.
6- As soon as available I will include a link to ZIP-Files with all the images
and HTML pages for easier downloading and offline printing.
CHASSIS - SECTION AD
| Overview - Print (1.55 MB)
- top |
Sub-Section |
Page |
| General Description |
AD.1 |
4 |
| Change of Anti-Lift Angle |
AD.2 |
5 |
| Dimensional Check |
AD.3 |
6 |
| Longerons & Front Frame |
AD.4 |
9 |
| Crash Structure |
AD.5 |
12 |
| Body/Chassis Mounting Points |
AD.6 |
16 |
| Chassis External Paint Repairs |
AD.7 |
17 |
PAINT PROCEDURE - SECTION BH
| Overview - Print (1.33 MB)
- top |
Sub-Section |
Page |
| Paint Codes |
BH.1 |
2 |
| Safety Considerations |
BH.2 |
3 |
| Essential Working Practice |
BH.3 |
4 |
| Preperation for Primer |
BH.4 |
4 |
| Primer Application |
BH.5 |
5 |
| Preparation for Colour Coating |
BH.6 |
6 |
| Colour and Clear Coat Application |
BH.7 |
7 |
| Final Polishing |
BH.8 |
8 |
| Paint Procedure for RRIM Components |
BH.9 |
9 |
| Paint Removal |
BH.10 |
10 |
| Paint Rectification Procedures |
BH.11 |
10 |
x x x x x x x * x x x x x x x x x x x x x x x
Some of the procedures detailed in this section are based
on those used in the manufacture of Lotus cars, and start with the bare composite
bodyshell. These sections are included only for general guidance in repair work,
and do not constitute a complete service repair procedure. Note that different
oven temperatures and thinners may be necessary dependent on the level of trim
of the body, type of oven etc.
BODY REPAIR - SECTION BJ
| Overview - Print (7.87 MB)
- top |
Sub-Section |
Page |
Lotus Composite Body Features
|
BJ.1 |
2 |
| Body Care |
BJ.2 |
3 |
| Body Structure |
BJ.3 |
4 |
| Accident Damage Assessment |
BJ.4 |
5 |
| Resin and Gel Mix |
BJ.5 |
6 |
| Basic Bonds and Joints |
BJ.6 |
8 |
| Superficial Defect Repairs |
BJ.7 |
8 |
| Replacement Undertray Sections and Panels |
BJ.8 |
9 |
| Bobbin Inserts |
BJ.9 |
10 |
| Undertray Assembly Damage Assessment |
BJ.10 |
15 |
| Repair of Minor Cracks and Gel Cracks |
BJ.11 |
16 |
| Repair of Minor Surface Non Structural Damage |
BJ.12 |
19 |
| Introduction and Sequence of Bonded Panel Removal |
BJ.13 |
20 |
| Removal and Replacement of Sill Section |
BJ.14 |
22 |
| Removal and Replacement of Sill Without Removing 'A' and 'B' Post Covers |
BJ.15 |
25 |
| Remove Rear Top Shell |
BJ.16 |
28 |
| Remove Transom |
BJ.17 |
28 |
| Remove Lower Quarter Panels |
BJ.18 |
29 |
| Remove 'B' Post Cover |
BJ.19 |
30 |
| Remove 'A' Post Cover |
BJ.20 |
30 |
| Remove Sill |
BJ.21 |
31 |
| Remove 'B' Post Diaphragm |
BJ.22 |
31 |
| Remove Rear Bulkhead |
BJ.23 |
32 |
| Introduction and Sequence of Bonded Panel Fitment |
BJ.24 |
33 |
| Fit Front Bulkhead |
BJ.25 |
36 |
| Fit Demist Duct Assembly to Front Bulkhead |
BJ.26 |
38 |
| Fit HVAC Duct Plenum to Front Bulkhead |
BJ.27 |
39 |
| Fit Steering Column Infill to Front Bulkhead |
BJ.28 |
40 |
| Fit Rear Bulkhead |
BJ.29 |
42 |
| Fit 'B' Post Diaphragm |
BJ.30 |
43 |
| Fit Sill Infill and Sill |
BJ.31 |
45 |
| Fit. 'A' Post Cover |
BJ.32 |
47 |
| Fit 'B' Post Cover |
BJ.33 |
48 |
| Fit Rear Quarter Lower Panel |
BJ.34 |
49 |
| Fit Rear Transom |
BJ.35 |
51 |
| Fit Rear Top Shell |
BJ.36 |
52 |
| Fit Fuel Filler Rebate |
BJ.37 |
54 |
| Fit Battery Tray to Undertray |
BJ.38 |
55 |
| Fit Fuel Strap Mounting Strengthening Bracket |
BJ.39 |
56 |
| Fit 3 Centre Console Mounting Bracket |
BJ.40 |
58 |
| Introduction to Undertray Repairs |
BJ.41 |
59 |
| Repair Front Quarter Section of Undertray |
BJ.42 |
60 |
| Repair Front Half Section of Undertray |
BJ.43 |
69 |
| Repair Centre Section of Undertray |
BJ.44 |
76 |
| Repair Mid Section of Undertray |
BJ.45 |
81 |
| Repair Rear of Undertray |
BJ.46 |
90 |
| Fit Outrigger to Undertray |
BJ.47 |
93 |
| Fit Scuttle Beam |
BJ.48 |
95 |
| Repair Fibre Glass Damage Around Bobbin |
BJ.49 |
96 |
| Fit Bobbins to Undertray |
BJ.50 |
97 |
| Fit 'B' Post Tie Brace |
BJ.51 |
99 |
| Jigs Ect. |
BJ.52 |
100 |
| Legislation |
BJ.53 |
103 |
BODY FITTINGS - SECTION BK
| Overview - Print (9.2 MB)
- top |
Sub-Section |
Page |
| Door Assemblies |
BK.1 |
2 |
| Door Latch Mechanism |
BK.2 |
4 |
| Door Window Glass |
BK.3 |
8 |
| Door Window Lift Mechanism |
BK.4 |
14 |
| Door Mirrors |
BK.5 |
14 |
| 'A' Post Panels |
BK.6 |
15 |
| Front Topshell |
BK.7 |
15 |
| Front Bumper/Spoiler |
BK.8 |
19 |
| Rear Bumper |
BK.9 |
20 |
| Bonnet Panel |
BK.10 |
22 |
| Boot Lid |
BK.11 |
22 |
| Roof Stowage Lid |
BK.12 |
24 |
| Soft Top Roof |
BK.13 |
27 |
| Headlamp Mechanism |
BK.14 |
30 |
| Windscreen & Mirror Plinth |
BK.15 |
40 |
| Windscreen Pillar Weatherstrips |
BK.16 |
45 |
| Windscreen Frame |
BK.17 |
47 |
| Body Removal |
BK.18 |
51 |
| Addendum 1 - Water Ingress; areas of attention |
ADDENDUM 1 |
55 |
| Addendum 2 - Replacement of Fold Back Headlamps by Single Pivot Type |
ADDENDUM 2 |
74 |
| Addendum 3 - 'B' Post Tie Bar Setting Procedure |
ADDENDUM 3 |
82 |
| Addendum 4 - Identification of Weatherstrips |
ADDENDUM 4 |
84 |
FRONT SUSPENSION - SECTION CE
| Overview - Print (1.16 MB)
- top |
Sub-Section |
Page |
| General Description |
CE.1 |
3 |
| Geometry |
CE.2 |
3 |
| Adjustments |
CE.3 |
4 |
| Suspension Disassembly |
CE.4 |
6 |
| Suspension Re-assembly |
CE.5 |
9 |
| Hub Bearing Replacement |
CE.6 |
10 |
REAR SUSPENSION - SECTION DD
| Overview - Print (1.09 MB)
- top |
Sub-Section |
Page |
| General Description |
DD.1 |
3 |
| Geometry |
DD.2 |
3 |
| Adjustments |
DD.3 |
4 |
| Suspension Disassembly |
DD.4 |
5 |
| Suspension Re-assembly |
DD.5 |
8 |
| Hub Bearings |
DD.6 |
10 |
ENGINE - SECTION EC
| Overview - Print (7.96 MB)
- top |
Sub-Section |
Page |
| General Description & Torque Charts |
EC.1 |
3 |
| Lubrication System |
EC.2 |
11 |
| Engine Maintenance Operations |
EC.3 |
14 |
| Camshaft Drive Belt |
EC.4 |
16 |
| Water Pump |
EC.5 |
20 |
| Common Chamber, Fuel Injectors & Lower Manifold |
EC.6 |
20 |
| Hydraulic Valve Lifters |
EC.7 |
23 |
| Cylinder Head Assembly |
EC.8 |
|
| Oil sump |
EC.9 |
28 |
| Oil Pump Assembly |
EC.10 |
37 |
| Engine Removal/Replacement |
EC.11 |
38 |
| Cylinder Block, Pistons & Connecting Rods |
EC.12 |
41 |
| Crankshaft & Main Bearings |
EC.13 |
44 |
| Turbocharger |
EC.14 |
52 |
| Engine Mountings |
EC.15 |
59 |
| Special Tools |
EC.16 |
62 |
TRANSMISSION - SECTION FF
| Overview - Print (4.44 MB)
- top |
Sub-Section |
Page |
| Main Data |
FF.1 |
3 |
| General Description |
FF.2 |
3 |
| Lubrication |
FF.3 |
4 |
| Gearchange Cable Adjustment |
FF.4 |
5 |
| Gearchange Cable & Gearlever Mechanism Replacement |
FF.5 |
6 |
| Transmission Assembly Removal |
FF.6 |
9 |
| Transmission Assembly Replacement |
FF.7 |
10 |
| Major Component Disassembly |
FF.8 |
11 |
| Major Component Assembly |
FF.9 |
16 |
| Input & Output Shaft Disassembly/Assembly |
FF.10 |
25 |
| Final Drive Disassembly/Assembly |
FF.11 |
31 |
| Selector Housing Disassembly/Assembly |
FF.12 |
34 |
| Driveshafts |
FF.13 |
35 |
| Fault Diagnosis |
FF.14 |
39 |
| Special Tools |
FF.15 |
40 |
WHEELS & TYRES - SECTION GD
| Overview - Print (0.6 MB)
- top |
Sub-Section |
Page |
| Alloy Wheels |
GD.1 |
2 |
| Tyres |
GD.2 |
2 |
| Spare Wheel & Tyre |
GD.3 |
2 |
| Winter Tyres |
GD.4 |
5 |
| Wheel/Tyre Assembly Balancing |
GD.5 |
6 |
STEERING - SECTION HC
| Overview - Print (2.19 MB)
- top |
Sub-Section |
Page |
| General Description |
HC.1 |
2 |
| PAS Fluid Check & Oil Change |
HC.2 |
4 |
| Steering Wheel & Column Assembly |
HC.3 |
5 |
| Outer & Inner Ball Joints & Gaiters |
HC.4 |
10 |
| PAS Pump & Testing Procedure |
HC.5 |
11 |
| Steering Rack Assembly Removal/Replacement |
HC.6 |
13 |
| PAS Rack Assembly Seal & Bush Replacement |
HC.7 |
14 |
| Manual Rack Assembly Adjustment & Bush Replacement |
HC.8 |
16 |
BRAKES - SECTION JE
| Overview - Print (2.4 MB)
- top |
Sub-Section |
Page |
| General Description |
JE.1 |
3 |
| Front Brake Pad Replacement |
JE.2 |
4 |
| Rear Brake Pad Replacement |
JE.3 |
5 |
| Parking Brake Mechanism |
JE.4 |
7 |
| Front Caliper Overhaul |
JE.5 |
9 |
| Rear Caliper Overhaul |
JE.6 |
11 |
| Brake Discs |
JE.7 |
15 |
| Brake Servo Unit |
JE.8 |
15 |
| Master Cylinder |
JE.9 |
17 |
| Proportioning Valves |
JE.10 |
17 |
COOLING SYSTEM - SECTION KD
| Overview - Print (1.53 MB)
- top |
Sub-Section |
Page |
| General Description |
KD.1 |
3 |
| Maintenance |
KD.2 |
4 |
| Drain/Refill Procedure |
KD.3 |
6 |
| Radiator Fans & Control |
KD.4 |
7 |
| Engine Cooling Radiator |
KD.5 |
8 |
| Chargecooler Radiator |
KD.6 |
10 |
| Oil Cooler Radiator |
KD.7 |
12 |
FUEL SYSTEM - SECTION LG
| Overview - Print (2.18 MB)
- top |
Sub-Section |
Page |
| General Description |
lg.1 |
4 |
| Precautions |
lg.2 |
5 |
| Fuel Pump/Sender Unit |
lg.3 |
5 |
| Fuel Tank |
lg.4 |
8 |
| Fuel Filter |
lg.5 |
14 |
| Fuel Filler Flap |
lg.6 |
14 |
| Fuel Filler Neck |
lg.7 |
16 |
|
Evaporative Emission Control System (EECS)
(Catalyst cars only)
|
lg.8 |
18 |
MAINTENANCE & LUBRICATION
Recommended Lubricants |
|
|
| Maintenance Schedule |
|
|
| Pre-delivery Inspection |
|
|
HEATING VENTILATION & AIR CONDITIONING - SECTION
PE
| Overview - Print (3.48 MB)
- top |
Sub-Section |
pe.Page |
General Description |
pe.1 |
2 |
| Climate Controls & Airflow Distribution |
pe.2 |
6 |
| Vacuum Pipework & Switching Logic |
pe.3 |
14b |
| Refrigerant Handling |
pe.4 |
16 |
| Refrigerant Pipework Precautions |
pe.5 |
16 |
| Evacuation & Charging Procedure |
pe.6 |
17 |
| Refrigerant Oil |
pe.7 |
18 |
| Compressor |
pe.8 |
20 |
| Climate Control Switches |
pe.9 |
20 |
| Air Intake/Blower Assembly |
pe.10 |
22 |
| Evaporator Assembly |
pe.11 |
23 |
| Heater/Distribution Unit |
pe.12 |
25 |
CLUTCH -SECTION QD
| Overview - Print (0.6 MB)
- top |
Sub-Section |
Page |
| General Description |
qd.1 |
2 |
| Clutch Cable |
qd.2 |
2 |
| Release Bearing & Fork |
qd.3 |
4 |
| Clutch Assembly |
qd.4 |
5 |
EXHAUST SYSTEM - SECTION SD
| Overview - Print (1 MB)
- top |
Sub-Section |
Page |
| General Description |
sd.1 |
5 |
| Exhaust System Mountings |
sd.2 |
7 |
| Clamps and Joints |
sd.3 |
8 |
| Heat Shields |
sd.4 |
9 |
TECHNICAL DATA - ENGINE - SECTION TDG
| Overview - Print (0.5 MB)
- top |
Page |
| General Specification |
|
| Cylinder Head |
2 |
| Valves |
3 |
| Valve Guides |
3 |
| Valve Seats |
3 |
| Valve Springs |
3 |
| Valve Lifters |
3 |
| Camshafts |
3 |
| Cylinder Block |
|
| Pistons & Rings |
4 |
| Connecting Rods |
5 |
| Crankshaft |
5 |
| Flywheel & Ring Gear |
|
| Oil Pump |
6 |
| Water Pump |
6 |
TECHNICAL DATA - VEHICLE - SECTION tTDH
| Overview - Print (0.7 MB)
- top |
Page |
| Dimensions |
|
| Capacities |
2 |
| Front Suspension |
2 |
| Rear Suspension |
|
| Steering |
3 |
| Wheels |
|
| Tyres |
|
| Brakes |
|
| Transmission |
4 |
| Clutch |
4 |
| Engine Cooling |
5 |
| Electrical Equipment |
|
| Fuel Consumption |
|
| Torque Settings |
|
INTERIOR TRIM - SECTION VD
| Overview - Print (1.82 MB)
- top |
Sub-Section |
Page |
| Door Trim Panels |
1 |
2 |
| Centre Tunnel Console |
2 |
3 |
| Instrument/Switch Panel (Fascia Mask) |
3 |
4 |
| Main Fascia |
4 |
7 |
| Sill Tread Plates |
5 |
7 |
| Speaker Boxes |
6 |
9 |
| 'B' Post Trim Panels |
7 |
11 |
| Capping Rail |
8 |
12 |
| Roof Stowage Shelf & Side Panels |
9 |
13 |
| Screen Surround Trim Panels |
10 |
14 |
| Seats |
11 |
15 |
| Seat Belts |
12 |
16 |
SERVICE BULLETINS