Section AA Introduction - Evora 400 Service Notes
FRONT COVER
INTRODUCTION
SERVICE NOTES CONTENTS
INTRODUCTION CONTENTS
PLEASE READ THESE TERMS CAREFULLY BEFORE USING THIS PUBLICATION
VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER
V.I.N. DECODER
MODEL HISTORY
AA,1 - JACKING LIFTING POINTS
AA.2 - FRONT UNDERTRAY
AA.3 - ENGINE BAY UNDERTRAY & DIFFUSER
AA.4 - VEHICLE RECOVERY
Section TDB Engine data
GENERAL
Section TDA Vehicle data
CONTENTS
DIMENSIONS & WEIGHTS
CAPACITIES, STANDARDS & APPROVED PRODUCTS
WHEELS & TYRES
CHASSIS RIDE HEIGHT POINTS
FRONT SUSPENSION
REAR SUSPENSION
ELECTRICAL
TRANSMISSION
CLUTCH
BRAKES
STEERING
FUEL CONSUMPTION
Section AB Chassis
CONTENTS
MAIN CHASSIS TUB
AB.1 - GENERAL DESCRIPTION
AB.2 - CHASSIS STRAiGHTNESS CHECK
AB.3 - REAR SUBFRAME
AB.4 - FRONT SUBFRAME
Section BD Body Fittings
CONTENTS
GENERAL PANEL OVERVIEW
BD.1 - RESERVOIR ACCESS HATCH
BD.2 - TAILGATE & REAR SPOILER
BD.3 - 'A' PANELS
BD.4 - FRONT CLAMSHELL
BD.5 - FRONT BUMPER & LICENCE PLATE PLINTH
BD.6 - REAR CLAMSHELL
BD.7 - REAR BUMPER
BD.8 - DOOR MIRRORS
BD.9 - DOOR SHELL, BEAM & HINGES
BD.10 - DOOR WEATHERSTRIP SEALS
BD.11 - DOOR WINDOW, GUIDE RAILS & LIFT MECHANISM
BD.12 - DOOR LATCH MECHANISM
BD.13 - WINDSCREEN REMOVAL/REPLACEMENT
BD.14 - TAILGATE GLASS
BD.15 - CABIN REAR WINDOW
BD.16 - REAR QUARTER LIGHT WINDOW
BD.17 - WHEELARCH LINERS
BD.18 - 'A' PILLAR TRIM
BD.20 - EXTERIOR GRILLES
BD.21 - REAR DIFFUSER
BD.22 - LOGO, DECAL & BADGING FITMENT
BD.23 - FRONT LIP SPOILER (GT 430 & 410 MODELS)
BD.24 - TAILGATE & REAR WING (CARBON FIBRE AS FITTED TO GT 430 & 410 MODELS)
Section CL Front suspension
CONTENTS
GENERAL ARRANGEMENT
CL.1 - GENERAL DESCRIPTION
CL.2 - GEOMETRY & ADJUSTMENTS
CL.3 - WISHBONE PIVOT BUSHES & SWIVEL JOINTS
CL.4 - ANTI-ROLL BAR (ARB)
CL.5 - HUB UNIT & HUB CARRIER
CL.6 - SPRING AND DAMPER ASSEMBLY
CL.7 - UPPER AND LOWER WISHBONE ASSEMBLIES
CL.8 - ADJUSTABLE SUSPENSION OPTION
Section DV Rear suspension
CONTENTS
Rear Suspension Layout
DV.1 - GENERAL DESCRIPTION AND SERVICE SCHEDULE INSPECTION
DV.2 - GEOMETRY & ADJUSTMENTS
DV.3 - WISHBONE PIVOT BUSHES & SPHERICAL JOINTS
DV.4 - ANTI-ROLL BAR (ARB)
DV.5 - HUB UNIT AND HUB CARRIER
DV.6 - SPRING AND DAMPER ASSEMBLY
DV.7 - UPPER AND LOWER WISHBONE ASSEMBLIES
DV.8 - ADJUSTABLE SUSPENSION OPTION
Section EP Engine
CONTENTS
EP.1 - INTRODUCTION
EP.2 - ENGINE ACCESS PANEL
EP.3 - ENGINE OIL MAINTENANCE
EP.4 - AIR BOX CASING & CLEANER ELEMENT INSPECTION/REPLACEMENT
EP.5 - AUXILIARY DRIVE BELT
EP.6 - ENGINE REMOVAL/REPLACEMENT
EP.7 - ENGINE SPECIAL TOOLS
EP.8 - ENGINE REPAIR
EP.9 - CYLINDER NUMBERING
EP.10 - ENGINE MANAGMENT COMPONENT LOCATION
EP.11 - EXHAUST SYSTEM
EP.12 - ENGINE PROTECTION VALVE SYSTEM
EP.13 - SUPERCHARGER
EP.14 - RH BANK VVT OIL FEED PIPE
EP.15 BAFFLED SUMP ASSEMBLY
Section EMD Engine management
CONTENTS
Cylinder Numbering - viewed from above
EMD.1 - DIAGNOSTIC TROUBLE CODE (DTC) LIST
EMD.2 - COMPONENT FUNCTION
EMD.3 - COMPONENT LOCATION
EMD.4 - DIAGNOSTIC GUIDE
EMD.5 - CAN BUS DIAGNOSTICS; LOTUS TECHCENTRE
Section FR Manual transmission
CONTENTS
GENERAL LAYOUT
FR.1 - GENERAL DESCRIPTION
FR.2 - GEARCHANGE MECHANISM
FR.3 - LUBRICATION
FR.4 - DRIVE SHAFTS
FR.5 - TRANSMISSION REMOVAL/REPLACEMENT
FR.6 - TRANSMISSION OVERHAUL
FR.7 - TRANSMISSION OIL COOLING (if fitted
Section FA IPS Automatic transmission (Intelligent Precision Shift)
CONTENTS
GENERAL LAYOUT
FC1 - GENERAL DESCRIPTION
FC2 - GEAR CHANGE
FC.3 - PRND SELECTION
FC.4 - TRANSMISSION FLUID COOLING
FC.5 - TRANSMISSION FLUID LEVEL CHECKING, ADJUSTMENT AND DRAINING
FC. 6 - IGNITION SWITCH AND BATTERY DISCONNECTION
FC.7 - VEHICLE RECOVERY AND TOWING
FC.8 - TRANSMISSION DIAGNOSTIC TROUBLE CODES
FC.9 - DRIVESHAFTS
FC.10 - TRANSMISSION REMOVAL/REPLACEMENT
Section GT Wheels & tyres
CONTENTS
GT.1 - GENERAL DESCRIPTION
GT.2 - TYRE PRESSURE MONITORING SYSTEM (TPMS)
GT.3 - WHEELS
GT.4 - WHEEL BOLTS
GT.5 - TYRES
GT.6 - WINTER TYRES & SNOW CHAINS
GT.7 - PUNCTURED TYRE EMERGENCY INFLATOR
GT.8 - TPMS CONFIGURATION AFTER COMPONENT REMOVAL/REPLACEMENT
Section HF Steering
CONTENTS
Column and Rack Assembly Schematic
HI.1 - GENERAL DESCRIPTION
HF.2 - POWER STEERING RACK OPERATION
Power Steering Schematic (RHD with oil cooler shown)
HF.3 - PAS FLUID CHECK & REFILL PROCEDURE
HF.4 - STEERING WHEEL
HF.5 - IGNITION LOCK BARREL
HF.6 - IGNITION SWITCH
HF.7 - STEERING COLUMN ASSEMBLY
HF. 8 - TRACK ROD ENDS & RACK GAITERS
HF.9 - STEERING RACK ASSEMBLY REMOVAL/REPLACEMENT
HF.10 - PAS PUMP & TESTING PROCEDURE
HF.11 -PAS PUMP REMOVAL & INSPECTION
HF. 12 - POWER STEERING RESERVOIR REMOVAL/REPLACEMENT
HF.13 - PAS COOLER PIPE REMOVAL/REPLACEMENT
Section JP Brakes
CONTENTS
GENERAL LAYOUT
JP.1 - GENERAL DESCRIPTION
JP.2 - TELL TALE LAMPS
JP.3 - BRAKE FLUID CHECK & CHANGE
JP.4 - BRAKE PAD REPLACEMENT (front and rear)
JP.5 - PARKING BRAKE MECHANISM
JP.6 - BRAKE DISCS
JP.7 - BRAKE CALLIPERS
JP.8 - BRAKE MASTER CYLINDER, RESERVOIR AND HOSES
JP.9 - VACUUM SERVO UNIT
JP.10 - PEDAL BOX ASSEMBLY
JP.11 ANTI-LOCK BRAKING OPERATION
JP.12 - ABS/ESP MODULE UNIT
JP.13 - ABS/ESP MODULE SPECIAL FEATURES
JP.14 - WHEEL SPEED SENSORS
JP. 15 - STEERING ANGLE SENSOR
JP. 16 - YAW RATE SENSOR
JP.17 - DATA LINK CONNECTOR (DLC)
JP.18 - CAN BUS DIAGNOSTICS; LOTUS TECHCENTRE
JP.19 - ‘LOTUS TECHCENTRE’ CHECKING PROCEDURES
Section KT COOLING
CONTENTS
KT.1 - GENERAL DESCRIPTION
KT.2 ‑ MAINTENANCE
Kt.3 ‑ DRAIN/REFILL PROCEDURE
KT.4 - MAIN RADIATOR PACK, COOLING FANS & AUXILIARY RADIATOR
KT.5 - CONTROL OF RADIATOR FANS, ENGINE BAY FAN & COOLANT RECIRCULATION PUMP
KT.6 - RADIATOR FEED & RETURN PIPES
KT.7 - ENGINE OIL COOLER
KT.8 - SUPERCHARGER CHARGE COOLER
Section LP FUEL SYSTEM
CONTENTS
Fuel System Layout
LP.1 - GENERAL DESCRIPTION
LP.2 - FUEL REQUIREMENTS & FILLING
LP.3 - FUEL FILLER FLAP, SOLENOID, FILLER NECK & HOSE
LP.4 ‑ PRECAUTIONS & FUEL LINE DISCONNECTION
LP.5 - FUEL PUMP/TANK SENDER
LP.6 - FUEL TANK
LP.7 - FUEL SUPPLY TESTING
LP.8 - CHARCOAL CANISTER
Section MH ELECTRICS
CONTENTS
Electrical Component Location
MH.1 -GEMINI 7590 VEHICLE SECURITY ALARM
MH.2 - ELECTRIC WINDOWS
MH.3 - DOOR MIRRORS
MH.4 - SWITCHES & INSTRUMENTS - DRIVER'S INFORMATION
MH.5 - FUSEBOX AND CONTROL MODULE LOCATIONS
MH.6 - AUDIO EQUIPMENT
MH.7 - BATTERY, BATTERY CABLE, EARTHING POINTS & INERTIA SWITCHES
Mh.7a - LITHIUM ION BATTERY (if fitted)
MH.8 - HARNESS ROUTING
MH.9 - WIPER MECHANISM/WINDSCREEN & HEADLAMP WASHER RESERVOIR
MH.10 - HEADLAMP ASSEMBLIES
MH.11 - BULB REPLACEMENT
MH.12 - REVERSE PARK SENSOR SYSTEM (IF FITTED)
Section MH CIRCUIT DIAGRAMS
CONTENTS
FUSE BOX LAYOUT
COLOUR CODES
EMS CONNECTOR PIN OUT CHART
MH.1 - CIRCUIT DIAGRAMS
ABBREVIATIONS
Section MH.1a FEDERAL EVORA 400 CIRCUIT DIAGRAMS
CONTENTS
FUSE BOX LAYOUT
HARNESS AND WIRE COLOUR CODES
EMS CONNECTOR PIN OUT CHART
MH.1a - CIRCUIT DIAGRAMS
ABBREVIATIONS
Section OM MAINTENANCE & LUBRICATION
CONTENTS
FLUID CHANGE INTERVALS
MAINTENANCE SCHEDULE - EVORA
MAINTENANCE SCHEDULE - EVORA GT & SPORT MODEL RANGE
PRE-DELIVERY INSPECTION / INITIAL ACCEPTANCE FORM
PRE-DELIVERY & PAINT MARK UP SHEET
Section QR CLUTCH
CONTENTS
Clutch System General Layout
QR.1 - GENERAL DESCRIPTION
QR.2 - CLUTCH PEDAL
QR.3 - HYDRAULIC RELEASE SYSTEM
QR.4 - CLUTCH ASSEMBLY
QR.5 - CLUTCH POTENTIOMETER
Section VG INTERIOR TRIM
CONTENTS
FASCIA STRUCTURE
VG.1 - DOOR TRIM PANEL REMOVAL
VG.2 - DOOR TRIM PANEL REPLACEMENT
VG.3 - DOOR SILL TRIM PANEL, UPPER SILL TRIM PANEL & SILL TRIM CARPET
VG.4 - UPPER AND LOWER STEERING COLUMN SHROUD TRIMS
VG.5 - WINDSCREEN 'A' PILLAR TRIM PANELS & 'B' PILLAR TRIMS
VG.6 - CENTRE CONSOLE
VG.7 - LOWER FASCIA DASH PANELS
VG.8 - UPPER PANEL/FASCIA TRIM PANELS
VG.9 - INSTRUMENT BINNACLE/SWITCH COVER PANELS
VG.10 - INSTRUMENT/FASCIA PANEL
VG.11 - FRONT SEAT REMOVAL
VG.12 - REAR SEAT, ISOFIX SYSTEM & TETHER MOUNTS
VG.13 - HEADLINER
VG.14 - REAR QUARTER PANELS
VG.15 - REAR WINDOW SURROUND/BULKHEAD PANEL TRIM
VG.16 INSTRUMENT PANEL CLOSURE TRIM
VG.17 FRONT SEAT REPAIRS
Section WP SEAT BELTS & AIRBAG SYSTEM
CONTENTS
Supplementary Restraint System Main Components & Location
WP.1 - GENERAL DESCRIPTION
WP.2 - AIRBAG TELL TALE
WP.3 - DATA LINK CONNECTOR (DLC)
WP.4 - TROUBLE CODES & BASIC DIAGNOSIS
WP.5 - CAN BUS DIAGNOSTICS; LOTUS TECHCENTRE
WP.6 - SAFETY PRECAUTIONS, SHIPPING, STORAGE & DISPOSAL
WP.7 - THEORY OF OPERATION
WP.8 - SRS/SENSOR & DIAGNOSTIC MODULE (SDM)
WP.9 - DRIVER AIRBAG MODULE
WP.10 - ROTARY CONNECTOR
WP.11 - PASSENGER AIRBAG MODULE & PAB DEFEAT SWITCH
WP.12 - SEAT BELTS & PRE-TENSIONERS
WP.13 - SIDE AIRBAGS (FEDERAL MARKETS ONLY)
