2005 LOTUS ELISE remove

- The hexagon headed drain plug located at the bottom of the final drive casing, should be removed immediately after a run when the oil is warm, taking suitable precautions against
scalding.
- Clean the plug, fit a new sealing washer and refit securely.
- Refill to the level plug hole as detailed above.
Servicing & Maintenance
105
f131
Transmission
filler/level plug
Drain plug

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Cooling SystemThe engine cooling system uses a header tank to ensure that
the system remains completely filled, and also to accommodate
expansion of the coolant with increasing engine temperature.
The tank is mounted at the left hand side of the engine bay, and is fitted with a 108 kPa (15 psi) pressure cap to raise the boiling point of the coolant to over 120°C (250°F).
WARNING:
• Do NOT attempt to remove the pressure cap or air bleed plug from the header tank when the engine is warm
as serious scalding could result from boiling water

and/or steam.
• Coolant is hazardous to your health and may be fatal

if swallowed.
• Keep coolant out of reach of children.
• Coolant is hazardous to animals and may be fatal if

swallowed. Clean up spilled coolant and do not leave in
open containers.
The level of coolant in the translucent header tank will rise
as the engine warms up, and fall as it cools down, and under
normal circumstances it should not be necessary to add any
coolant to the system between services. If overfilled, the excess
coolant will be ejected when the engine is warm. If under filled, overheating may result.
Servicing & Maintenance
106
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Air bleed plugCoolant header tank cap

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As a precaution, every week when the engine is completely
COLD, and without disturbing the filler cap, check that the level of coolant in the translucent tank is between the ‘FULL’
and ‘LOW’ marks moulded on the front of the tank. If topping
up is required, wait until the coolant has fully cooled before
turning the cap a quarter turn counterclockwise and allowing any remaining pressure to escape. Only then may the cap be
completely unscrewed. In order to maintain protection from freezing damage and
metal corrosion, use only an approved coolant mixture (see below) to top up the tank to the ‘FULL’ mark. Refit the cap, and
turn clockwise until the leg on the cap locates in the slot at the
front of the tank.
NOTICE: If the cap is removed when the engine is warm, the coolant may boil and a small coolant loss may occur. The com
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pletely cold header tank level should be checked at the first subsequent opportunity.
Cooling Fans
: Two cooling fans are fitted below the radiator in
the air intake duct. The fans are energised at high coolant tem
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peratures, or when the air conditioning (if fitted) is selected. The
fans will also run if certain types of engine fault are detected, and
may operate during a 20 minute period following ignition switch off to prevent ‘hot soak’ boiling. An electric coolant circulation pump may also be heard running during this period.
WARNING: Keep hands, tools and clothing away from the radiator
cooling fan area, as personal injury could result from the
fans starting up without warning.
At service intervals, the air duct and matrices of the engine
cooling radiator, a.c. condenser and oil coolers, should be
checked externally for clogging by insects, leaves or other debris,
and if necessary, a water jet used to clear the finning. Take care not to damage or distort the delicate finning of the radiator or
the cooling performance will be degraded.
Anti-Freeze/Corrosion Inhibitor It is most important that the correct coolant specification is
used in order to inhibit boiling and protect the engine and heat
Servicing & Maintenance
107

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Air Cleaner ElementThe air filter should be inspected at intervals dependent on
the operating conditions. When the car is operated in a relatively
clean environment, the element should be renewed at intervals
specified in the Maintenance Schedule, but where a dusty or
smog laden atmosphere prevails, or other factors contribute to
filter contamination, more frequent replacement will be required
dependent on the level of pollution. A disposable folded paper type air cleaner element is fitted in
a housing at the left hand front of the engine bay. For access to
the element, the left hand rear wheel and wheelarch liner must
first be removed so this operation is best entrusted to your dealer.
Before opening the air cleaner housing, the wheelarch area
should be cleaned to reduce the possibility of filter or housing contamination with road dirt. To open the filter housing, release the two spring clips at the
outboard end of the housing, and hinge open sufficiently to allow
the element to be removed. If necessary, remove the air intake scroll for improved access. Clean the inside of the housing, including the joint faces,
taking care not to contaminate the ‘clean’ engine side of the as
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sembly. Fit the new filter element into position with the shallow
side towards the engine, and taking care to ensure that the two
hinges of the filter housing are properly mated, and that the filter
is seated correctly, close the housing and secure with the two
spring clips. Refit the wheelarch liner and rear wheel.
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AIR CLEANER ELEMENT
Servicing & Maintenance
113

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ding.
Tire Chains In extreme weather conditions, Lotus approves the fit
-
ment of Pewag Neon X3 - NX373 snow chains, used only in conjunction with winter Tires (see above) and fitted only on the rear wheels. Close attention should be paid
to the fitting and tensioning instructions supplied with the chains, and the chains should be removed as soon as
road conditions allow.
Uniform Tire Quality Grading Quality grades can be found where applicable on the
tire sidewall between tread shoulder and maximum section
width. For example:
Treadwear 200 Traction AA Temperature A
The following information relates to the system de
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veloped by the United States National Highway Traffic
Safety Administration, which grades Tires by treadwear, traction and temperature performance (This applies only
to cars sold in the United States). The grades are moulded on the sidewalls of most
passenger car Tires. The Uniform Tire Quality Grading system does not apply to deep tread, winter-type snow
Tires, space-saver or temporary use spare Tires, Tires with nominal rim diameters of 10 to 12 inches (25 to 30 cm), or to some limited-production Tires. While the Tires available on Lotus cars may vary with
respect to these grades, they must also conform to federal safety requirements.
Treadwear The treadwear grade is a comparative rating based
on the wear rate of the tire when tested under controlled
conditions on a specified government test course. For example, a tire graded 150 would wear one and a half
(1.5) times as well on the government course as a tire graded 100. The relative performance of Tires depends
upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in
driving habits, service practices, and differences in road
Tires & Wheels
120

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Directions for use of the aerosol: Before using, carefully read all the instructions on the canister, or on any literature
accompanying the product. The following instructions ap
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ply to the use of Holts Tireweld:
1. Remove the object causing the puncture, and position the wheel with the puncture site lowermost. Deflate tire
fully.
2. Shake the can vigorously. In cold conditions, warm the
can using the car's heater outlets, or by body warmth.
3. Screw the aerosol tube onto the tire valve, remove the cap, hold the can upright and press the button until the
tire is firmly inflated.
4. Immediately drive for 6 - 12 miles (10 - 20 km) (or to the tire repair facility if nearer) in a moderate manner and not exceeding 30 mph (45 km/h), to allow the sealant
to spread. Then check and adjust the tire pressure as necessary.
5. Have the tire professionally repaired or replaced at the earliest opportunity, and until such time, limit speed to
30 mph (45 km/h) with a moderate driving manner. Note that some tire repairers may make an additional charge
for cleaning the sealant off the tire before repair, and
that any subsequent repairs may not be guaranteed.
6. Renew the puncture repair aerosol.
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TIRE INFLATOR AEROSOL
Tires & Wheels
125

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WheelsEnsure that only original equipment, or Lotus approved wheel
and tire combinations are fitted. After the car has been used
on track, or in competition conditions, the wheels should be removed and thoroughly inspected for damage.
WARNING: After striking a pothole or kerb, the wheels should be
removed and the wheel and tire thoroughly inspected for
damage. Renew the wheel and /or tire if necessary. Safety
considerations should always be paramount and new parts
fitted in any cases of doubt.
Wheel Bolts The wheel bolts used on the Elise are of a special design to
suit the small diameter fixing tunnels in the wheel centres. The bolts have a 10 spline socket head, for which a special extension
tool is supplied with the car. A 17mm a/f deep socket and 1/2
inch square drive wrench should be applied to the extension tool,
with a tightening torque of 77 lbf.ft (105 Nm) required. To protect against wheel theft, one of the four bolts securing
each wheel is key coded, and requires a corresponding coded
socket wrench and 1/2 inch square drive extension. Rotate the coded socket until full engagement with the bolt head is ensured and take care to maintain the extension tool perpendicular to
the wheel face before applying release torque.
NOTICE: It is not recommended to use hammer action air tools on the coded bolts - use only manual tools.
Both the standard extension and coded socket tools are
stowed in the car tool kit, and should remain with the car at all
times to ensure that servicing may be performed. The key code
included in the tool kit should be recorded and kept safely with
the car documents, in case a replacement socket tool needs
to be ordered.
Wheel Alignment and Tire Balance The wheels on your car were aligned and balanced carefully
during the manufacture of your car to give you the longest tire
life and best overall performance.
Tires & Wheels
126

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ELECTRICAL
BATTERY
WARNING:
POISON/DANGER - CAUSES SEVERE BURNS KEEP OUT
OF REACH OF CHILDREN.
• Contains sulphuric acid - avoid contact with skin, eyes or clothing. If in contact with skin or eyes; flush with copious amounts of water. Remove contaminated clothing. Seek
immediate medical attention. If ingested; seek immediate
medical attention. Do not induce vomiting or give fluids
to drink.
• Batteries produce explosive gases. Keep sparks, flames and cigarettes away. Ventilate when charging or using in
enclosed space. Always shield eyes when working near
batteries.
RISK OF SHORT CIRCUIT AND FIRE
• Observe all warning notes on the battery.
• Disconnect the battery during all work on the electrical system.
• Do not lay tools or other metal objects on the battery as they could cause a short circuit across the battery
terminals.
Battery Access The ‘maintenance free’ battery is located at the left hand
front of the rear luggage compartment. No routine inspection or topping up of the electrolyte is required, but at inter vals
specified in the Maintenance Schedule, the battery terminals
should be checked for security and condition, and protected
with petroleum jelly. For access to the terminals, first unclip the battery cover
from the floor and ease the cover from around the left hand rear corner of the battery.
Disconnecting the Battery
WARNING: Failure to follow the correct battery disconnection pro
-
cedure detailed below could result in serious burns.
Electrical
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