Lotus Elise / Lotus Exige. Manual - part 31

Page 13

 

 

Lotus Service Notes   

 

 

     Section EH

13.  Fit two engine lifting brackets T000T1437S to the left hand front and right hand rear of the cylinder head. 

Sling support the power unit before releasing the RH and LH engine mounting brackets. 

 17.  Carefully hoist the power unit from the car, whilst monitoring for any remaining connections.

 

Refit the unit in reverse order to removal with the following notes:

- 

Before re-fitting a driveshaft, first renew the round section circlip on the end of the left hand inboard joint 

spigot shaft, and lubricate the circlip with grease.  Also, check the condition of the transmission output seal, 

and renew if necessary.  Lubricate the lip of the seal with transmission oil, and grease the corresponding 

shoulder on the driveshaft (C.V. joint) spigot, to reduce the danger of damaging the seal on assembly.  

- 

Carefully insert the driveshaft into the transmission, with, on the left hand shaft, the two ends of the circlip 

positioned lowermost, and rotate the shaft if necessary to engage the splines.  Press the inboard joint outer 

until a click indicates the engagement of the retaining circlip, if necessary using a brass drift and hammer.  

Pull on the body to ensure its security.  On the right hand shaft, fit the bolts securing the extension shaft 

bearing to the engine mounted bracket, and torque to 64 Nm.

- 

Refer to section DH for rear suspension assembly details.

- 

For coolant refilling procedure, refer to section KH.

- 

For transmission details and gear cable adjustment, refer to section FJ.

EH.4 - SPECIAL TOOLS

 

The following engine special tools are available under Lotus part number:

Engine Lift Bracket           T000T1437S    2 off     

Bolt, engine lift bracket        T000T1440S     2 off

Oil Filter Wrench            T000T1441F     1 off

Valve Clearance Adjuster Set    T000T1442F     1 off

Crankshaft Pulley Holding Tool    T000T1443F     1 off

Flange Holding Tool          T000T1444F     1 off

    Engine lifting brackets

                                                                    

e229

 

 

Lotus Service Notes   

 

 

     Section EH

Page 14

EH.5 - ENGINE MANAGEMENT COMPONENT LOCATION

Key to engine management component location drawing

1.  Electronic Control Unit (ECU).

2.  Multi-function relay unit.

3.  Oil control valve for variable valve lift.

4.  Camshaft position sensor.

5.  Fuel injector.

6.  Knock sensor.

7.  Oil control valve for variable valve timing.

8.  Crankshaft position sensor.

9.  Plug top coil.

10.  Coolant temperature sensor.

11.  Pre-catalyst oxygen sensor.

12.  Post-catalyst oxygen sensor.

13.  Oil pressure switch.

14.  Throttle position sensor.

15.  Vacuum solenoid for intake flap valve.

16.  Mass airflow sensor.

17.   Idle Air Control (IAC) valve (prior '06 M.Y.)

For component replacement procedures, refer to manual B120T0327J.  For diagnostic codes, refer to Section 

EMP.

        1

                          2 

                                           4

                                 3                               5 

   

                                                              6

 

     

               17                         

                                                                  7

        16

                                                                  8

   15

                             

                                                        9

  14

 

 

13 

 

 

 

 

 

 

 

   10

 

 

 

 

 

12 

 

       11   

 

Page 15

 

 

Lotus Service Notes   

 

 

     Section EH

EH.6 - ELISE S SUPPLEMENT

The Elise S, introduced in May 2006 uses the Toyota '1ZZ-FE' engine instead of the '2ZZ-GE' fitted in the 

Elise 111R.  The two engines are similar in basic architecture, with the 2ZZ having been derived from the 1ZZ, 

and whilst the overhaul procedures are largely common, many of the principal components are different.  This 

section identifies the main differences between the two engine types.

Valve Mechanism

The 1ZZ uses the same VVT-i 'intelligent' variable intake valve timing system as used on 2ZZ, but without 

the intake and exhaust variable valve lift feature.  Valve clearance adjustment via selective cam followers rather 

than 'top hat' shims.  Airbox flap valve programmed to open at 5,000 rpm.  Lower rpm limits (see below).

Dimensions

The bore and stroke differ between the two engines, although the capacity difference favours the 2ZZ by 

only 2cc.  The 1ZZ is more undersquare with dimensions of 79.0 x 91.5mm producing 1794cc (2ZZ: 82.0 x 85.0 

= 1796cc).  The angle between intake and exhaust valves on the 1ZZ is 10° less at 33°, to permit a compact 

cylinder head without the requirement to accommodate variable valve lift.  The compression ratio is dropped 

from 11.5 to 10.0:1.

Cylinder Block

The open deck alloy cylinder block of the 1ZZ uses dry, thin wall, non-replaceable, cast iron cylinder liners 

(2ZZ uses integrated MMC cylinder walls).

Manifolds

The inlet manifold is moulded in plastic to reduce weight and heat transference, and incorporates a resona-

tor feature to optimise gas pulsations for mid-range performance.  A unique adaptor is used to link the manifold 

to the electronic throttle body which differs from the 2ZZ and other 1ZZ types.

The simplified exhaust manifold and downpipe dispense with the divider plate used on the 2ZZ.

Cooling System

The cooling system is largely unchanged, with all 1ZZ cars using the oil/water heat exchanger and no 

front mounted oil coolers.  The throttle body is heated as previously, although the feed and return connections 

differ in detail and no in-line throttle body thermostat is used.

Technical Data                        

 

                                   

1ZZ-FE            2ZZ-GE (reference)

Capacity                                 1794 cc            1796 cc

Bore                                     79.0 mm           82.0 mm

Stroke                                  91.5 mm           85.0 mm

Valve control                              VVT-i             VVTL-i

Compression ratio                           10.0:1             11.5:1

Compression pressure (250 rpm, normal run temp.)  - new 1500 kPa (218 psi)     1400 kPa (203 psi)

                                    - min. 1000 kPa (145 psi)     1000 kPa (145 psi)

Spark plugs   - type                         NGK BKR5EYA-11     NGK IFR6A-11

                                        Denso K16R-U11
            - gap                          1.0 ± 0.05mm        1.1 mm

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

                                        @ 6,200 rpm        @ 7,800 rpm

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

                                        @ 4,200 rpm        @ 6,800 rpm

Maximum continuous engine speed                6,800 rpm          8,000 rpm

Maximum transient engine speed                  7,150 rpm          8,500 rpm

Exhaust emissions (Euro 4 & LEV 1)    - CO          0.23 g/km          0.42 g/km

                            - HC          0.050 g/km          0.078 g/km

                            - NOx         0.0217 g/km         0.0121 g/km

                            - HC + NOx      0.0717 g/km         0.07921 g/km

                            - CO

2

 (combined)  196 g/km           208 g/km

 

 

Lotus Service Notes   

 

 

  Section EMP

Page 1

ENGINE MANAGEMENT

SECTION EMP

                                                     Sub-Section   Page

    Diagnostic Trouble Code List                              EMP.1    3

    'Lotus Scan' Diagnostic Tool                               EMP.2    43

    Engine Management Component Location                      EMP.3    45

    Mechanical Throttle Setting Procedure                         EMP.4    46

    2006 Model Year Electronic Throttle Control                      EMP.5    47

    Diagnostic Trouble Code Supplement - '06 M.Y.                   EMP.6    48

sn_emp_cyclone.indd   1

03/03/2006   11:03:33