Content .. 4 5 6 7 ..

Lotus Eleven/Elise/Exige. Manual - part 6

Page 10

Lotus Service Notes

Introduction

JACKING POINTS

Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas

shown in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a

4-point lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using

a 4-point lift, it is strongly recommended that for optimum stability and safety, positions B and D are used.

A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time

for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift.

B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use

with 4-point lift in conjunction with (C).

C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis

crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws

for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B).

D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower

wishbone rearmost mountings.

Jacking at any other point may damage the chassis or body structure and/or jeopardise safety.

ohs49sn

Page 1

Lotus Service Notes Section TDP

TECHNICAL DATA - ENGINE

SECTION TDP

Page

General ....................................................................................................................

Cylinder Block ..........................................................................................................

Cylinder Head ..........................................................................................................

Valves & Springs ......................................................................................................

Camshafts ................................................................................................................

Pistons .....................................................................................................................

Connecting Rods ......................................................................................................

Crankshaft ...............................................................................................................

Oil Pump ..................................................................................................................

Coolant Thermostat ..................................................................................................

Page 2

Lotus Service Notes Section TDP

GENERAL (for supercharged cars see section Exige S/C)

Type designation - All nat. asp.except Elise S

2ZZ-GE

- Elise S

1ZZ-FE

- 2011 Elise

1ZR-FAE

Configuration & no. of cylinders in-line 4 - -

Capacity 1796 cm

1794 cm³ 1598 cm

Bore 82.00 mm 79.00 mm 80.50 mm

Stroke 85.00 mm 91.50 mm 78.50 mm

Camshafts Chain drv DOHC - -

Valves 4VPC in pentroof - -

chambers

Valve control - inlet Variable timing Variable timing Variable timing

& 2 stage lift & lift

- exhaust Variable lift - Variable timing

Valve timing - inlet - low & med speed - open 33°BTDC to

10° TDC

- close 15°ATDC to

58°ATDC

- high speed - open 58° BTDC to

15° BTDC

- close 54° ABDC to

97° ABDC

- all speeds - open 48°BT to 5°BT 10°BT to 70°AT

- close 12°AT to 55°AT 70°AB to 60°BB

- exhaust - low & med speed - open 14° BBDC

- close 34° ATDC

- high speed - open 36° BBDC

- close 60° ATDC

- all speeds - open 42° BBDC 65°BB to 30°BB

- close 2° ATDC 1°BT to 34°AT

Compression ratio 11.5:1 10.0:1 10.7:1

Compression pressure (250 rpm) - new 1400 kPa 1500 kPa 1400 kPa

- service limit 1000 kPa - -

Firing order 1,3,4,2 - -

Spark plugs NGK IFR6A11 NGK BKR5EYA-11 Denso 20HR11

Spark plug gap 1.1 mm 1.0 ± 0.05 mm 1.0 - 1.1 mm

Maximum continuous engine speed 8000 rpm 6,800 rpm 6,800 rpm

Maximum transient engine speed 8500 rpm 7,000 rpm 7,000 rpm

Idle speed 850 rpm 850 rpm 760 rpm

Ignition system Direct ignition - -

Plug top coils - -

Fuel system Fully sequential - -

indirect injection, - -

Lotus T4 ECU - Lotus T6 ECU

Fuel requirement (minimum) Unleaded 95 RON - -

Peak power (1999/99/EC) 141 kW (192 PS) 100 kW (136 PS) 100kW(136 PS)

@ 7,800 rpm @ 6,200 rpm @ 6,800 rpm

Peak torque (1999/99/EC) 181 Nm 172 Nm 160 Nm

@ 6,800 rpm @ 4,200 rpm @ 4,400 rpm

Exhaust emissions - CO 0.42 g/km 0.23 g/km 0.27 g/km

- HC (THC) 0.078 g/km 0.050 g/km 0.064 g/km

- NMHC 0.058 g/km

- NOx 0.0121 g/km 0.0217 g/km 0.025 g/km

- HC + NOx 0.0901 g/km 0.0717 g/km

- CO

- pre '10 208 g/km 196 g/km

- 2010 on 196 g/km 179 g/km 155 g/km

Page 3

Lotus Service Notes Section TDP

2ZZ-GE 1ZZ-FE 1ZR-FAE

CYLINDER BLOCK

Material Aluminium alloy, Aluminium alloy, Aluminium alloy

MMC bores cast iron liners cast iron liners

Deck face flatness tolerance 0.05 mm - -

Cylinder bore diameter (mm) 82.000 - 82.013 79.000 - 79.013 80.500 - 80.633

CYLINDER HEAD

Material Aluminium alloy - -

Head face flatness tolerance 0.05 mm - -

Reface limit No machining - -

VALVES & SPRINGS

Valve seat angle in head 45° - -

Valve face angle 44.5° - -

Cold valve clearance (cam & follower) - inlet 0.10 - 0.16 mm 0.15 - 0.25 mm Hydraulic

- exhaust 0.24 - 0.30 mm 0.25 - 0.35 mm Hydraulic

Valve guide standout - inlet 15.3 - 15.7 mm 8.7 - 9.1 mm 9.0 - 10.3 mm

- exhaust 15.3 - 15.7 mm 8.7 - 9.1 mm 11.15 - 11.55

Valve spring free length - inlet 46.4 mm 45.9 mm 53.4 mm

- exhaust 46.5 mm 45.9 mm 53.4 mm

CAMSHAFTS

End float - new 0.04 - 0.14 mm 0.04 - 0.10 mm 0.06 - 0.16 mm

- service limit 0.15 mm 0.11 mm 0.17 mm

PISTONS

Diameter - @ 90° to pin, 12 mm from bottom edge 81.975 - 81.993 80.470 - 80.496

- @ 90° to pin, 25 mm from top edge 78.925 - 78.935

Ring gap - 110 mm from bore top - std. - no.1 0.25 - 0.35 mm -

- no.2 0.35 - 0.50 mm -

- oil rail 0.15 - 0.40 mm -

- max. - no.1 1.1 mm -

- no.2 1.2 mm -

- oil rail 1.1 mm -

- 50 mm from bore top -std. - no.1 0.20 - 0.30 mm

- no.2 0.30 - 0.50 mm

- oil rail 0.10 - 0.40 mm

- max. - no.1 0.50 mm

- no.2 0.70 mm

- oil rail 0.70 mm

Ring groove clearance 0.030 - 0.070 mm - 0.02 - 0.07 mm

CONNECTING ROD

Small end bush inside diameter 20.011 - 20.023 20.012 - 20.021 20.012 - 20.021

Big end side clearance 0.16 - 0.34 mm - -

CRANKSHAFT

Crankshaft endfloat - new 0.04 - 0.24 mm 0.04 - 0.24 mm 0.04 - 0.14 mm

- service limit 0.30 mm 0.30 mm 0.18 mm

Main journal diameter 47.988 - 48.000 - -

Crankpin diameter 44.992 - 45.000 43.992 - 44.000 43.992 - 44.000

Max. taper & out of round, journals & crankpins 0.02 mm 0.02 mm 0.004 mm

OIL PUMP

Oil pressure - idle, running temperature 39 kPa min. 29 kPa min. 25 kPa min.

- 3,000 rpm, running temperature 300 - 540 kPa 300 - 540 kPa 150 - 550 kPa

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