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Lotus Eleven/Elise/Exige. Manual - part 115

Lotus Service Notes Section PL

Page 19

Front mounting
spreader plate

Rear mounting
spreader plate

Radiator
mounting
panel

Front
mounting
bracket

Rear
mounting
bracket

Engine
cooling
radiator

Air conditioning
condenser

Fan fixing

Cooling fan

p105

Lotus Service Notes Section PL

Page 20

Release the radiator mounting panel from the crash structure and lift away the complete assembly.

To remove the radiator pack from the mounting panel, pull out the sealing foam, release the three bolts
securing each rear bracket to the panel, and the two bolts fixing each front bracket to the panel. Separate
the fans, condenser and radiator as necessary.

On re-assembly, note that the two angle brackets securing the rear of the condenser to the radiator duct,
are positioned below the condenser flange, and use a spacer washer at the adjacent fixing point to
replicate the flange thickness. Ensure that the sealing foam is refitted around the sides and rear of the
condenser, and that the spreader plates are fitted on top of the housing at the front fixing points.

10.

If a new condenser is fitted, add 30 cm³ of approved refrigerant oil to the system.

Use new 'O' rings on the pipe connections, and lubricate with refrigerant oil.

Using two spanners, tighten the condenser inlet connection to 25 - 30 Nm.

Using two spanners, tighten the condenser outlet connection to 20 - 25 Nm.

Recharge the system with 0.55 kg of R134a.

Refill the cooling system (see sub-section KH.3).

PL.9 - RECEIVER-DRIER

If the system has been open to at-

mosphere for any length of time, e.g. fol-
lowing accident damage or a burst hose or
damaged component, the receiver-drier
unit must be renewed, and should be the
last component to be fitted, and uncapped
only immediately prior to connection and
recharging.

The receiver-drier is clamped to a

mounting bracket at the front of the climate
chamber. If the receiver-drier is to be re-
placed, the refrigerant must first be recov-
ered using suitable equipment connected
to the service ports at the right hand front
of the engine bay.
-

Cap all pipes and ports immediately
after disconnection to prevent the in-
gress of dirt and moisture.

When reconnecting the pipes, use
new 'O' rings coated in an approved
refrigerant oil, and tighten to 20 - 25
Nm.

PL.10 - EXPANSION VALVE

The expansion valve is fitted onto the evaporator inlet and outlet pipes above the climate chamber, and

is accessible from within the front services compartment. To replace the valve:

Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.

Release the single M6 screw securing the clamp plate to the top of the expansion valve, and withdraw the
plate and both pipes from the valve. Immediately cap the pipes and ports to prevent the ingress of dirt
and moisture.

Radiator mounting panel

Inlet connection

Trinary switch

p107

Outlet
connection

Mounting

Receiver

Windscreeen

bracket

drier

Lotus Service Notes Section PL

Page 21

Release the two M5 screws from the counterbored holes in the top of the valve, securing the valve to the
evaporator pipes, and withdraw the valve from the pipes. Immediately cap the pipes and ports to prevent
the ingress of dirt and moisture.

Before refitting, renew all the connector 'O' rings, and coat with an approved refrigerant oil.

Fit the threaded clamp plate around the evaporator pipes, and secure the expansion valve onto the pipes
with the two M5 screws tightened to 5 - 6 Nm.

Use the second clamp plate to secure the two pipes to the expansion valve, tightening the single M6
screw to 7 - 9 Nm.

Recharge the system with 0.55 kg of R134a.

PL.11 - HEATER/EVAPORATOR/FAN UNIT

The heater matrix and a.c. evaporator are contained within a single housing together with the air blender

temperature control flaps. The housing is mounted in the chassis climate chamber where it is clipped to the fan
blower unit, and retained by a simple clamp bracket.

Note that the heater/a.c./blower unit is fitted the opposite way round between Rover and Toyota powertrain

cars: On 'Rover' cars, the blower unit is on the passenger side, and the air blend actuator on the rear of RHD
installations, and in front on LHD. On 'Toyota' cars, the blower is on the driver's side, and the air blend actuator
on the front of RHD cars and the rear of LHD.

Outlet to compresser

Inlet from receiver-drier

M6 clamp screw

'O' ring seal

Top clamp plate

M5 clamp screw (x2)

Expansion valve body

Lower clamp plate
(tapped)

'O' ring seal

Evaporator outlet pipe

Evaporator inlet pipe

p71

Lotus Service Notes Section PL

Page 22

To remove heater/evaporator/fan unit:
1.

Remove the front clamshell (see sub-section BR.6).

Remove the two air deflector/water shields, windscreen washer reservoir and ducting between heater/
a.c. unit and air distribution unit.

Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.

Disconnect the refrigerant pipes as necessary and remove the receiver-drier unit and mounting bracket.
Disconnect the outlet pipe from the expansion valve. Cap all pipes and ports immediately to prevent the
ingress of dirt and moisture.

Disconnect the hoses from the heater matrix and collect escaping coolant.

Unplug the wiring harness from the temperature flap motor, a.c. thermostat and fan motor.

Remove the clamping bridge retaining the unit into the chassis and release the overcentre clips securing
the unit to the fan blower housing. Withdraw the unit from the chassis together with the drain tube.

To refit heater/evaporator/fan unit:

Before refitting the unit, first ensure that the following components are fitted in the chassis:

Fresh air intake ducting/re-circulation valve assembly, retained in channel at front of chamber by single
clamp bracket. Check that re-circ. flap stepper motor harness is connected, and that the moulded plastic
water shield is fitted over the actuator.

-
-

Recirc. ducting is fitted in rear of chassis climate chamber

Earth cables are connected to chassis negative post at the left hand side of the chamber.

Rear circuit brake pipe is fitted between master cylinder and bulkhead connector.

Position the fan housing into the passenger side of the chassis chamber. Fit the drain tube into the base

of the heater/evap. unit and use a guide wire or similar to aid routing of the tube through the chassis crossmember
via the central aperture at the back of the chamber, as the unit is fitted into the chamber. Engage the lower
edges of the fan unit and heater/evap. unit before clamping together with the two overcentre latches. Retain
the assembly by fitting the bridging clamp bracket.

Continue re-assembly in reverse order to removal.

PL.12 - AIR DISTRIBUTION UNIT

The airflow distribution unit is mounted on top of the chassis scuttle, sandwiched between the underside

of the fascia top/demist duct and the chassis. The unit comprises several plastic mouldings bonded and
rivetted together to contain the rotary flap for windscreen/face level vents, and also the footwell flap. The
stepper motor for the rotary flap is mounted on the side of the unit.

To Remove
1.

Remove the front clamshell (see sub-section BR.6) and washer bottle and wiper mechanism (see sub-
section MP.8).

Remove the air trunking between the heater/a.c. unit and the distribution unit.

Release the fixings securing the heater water pipe to the chassis scuttle.

Drill out the rivets securing the distribution unit retaining bracket to the chassis scuttle.

Withdraw the unit from beneath the scuttle baffle panel, disconnecting the stepper motor harness plug
when access allows.

Content .. 113 114 115 116 ..