Lotus Elise / Lotus Exige. Manual - part 100

    

Lotus Service Notes                                 Section PL

Page 14

Refrigerant Pipework Fixing Torques

Refrigerant Pipework 'O' Rings

Key

Description

Qty

Thread

Pitch

Torque

1

Compressor to engine

3

M8

35 Nm

2

A.C. hoses to compressor

2

M6

10 Nm

3

Bulkhead connector, high pressure

2

3/4 - 16 UNF

1.6

25-30 Nm

4

Bulkhead connector, low pressure

2

1 1/16 - 14 UNS

1.8

35-40 Nm

5

High pressure blow off valve

1

3/8 - 24 UNF

1.1

10-13 Nm

6

High pressure pipe to condenser

1

3/4 - 16 UNF

1.6

25-30 Nm

7

Liquid line to condenser

1

5/8 - 18 UNF

1.4

20-25 Nm

8

Receiver-drier inlet/outlet pipes

2

5/8 - 18 UNF

1.4

20-25 Nm

9

Trinary switch to pipe

1

7/16 - 20 UNF

1.27

15-20 Nm

10

Clamp plate, pipes to expansion valve

1

M6

1

7-9 Nm

# Use refrigeration oil only, smear on "o" rings and threads prior to assembly

(Gloves should be worn when handling refrigeration oil - see data sheet)

10

   F

9

C

E

   1

4
C

D

2
B

8
E

         2
         A

3
D

3
D

7
E

4

5

C

E

6
D

        p75b

Key

Description

Size

Part Number 

A

Suction line to compressor

18mm o.d.

A120P6002H

B

High pressure line to compressor

15 mm o.d.

A120P6001H

C 

Suction line bulkhead connectors and expansion valve to 
suction line

17mm i.d.

A082P6081F

D

High press. line bulkhead connectors, cond. inlet, exp. valve to 
evaporator

11mm i.d.

A082P6079F

E

High pressure valve, condenser outlet, rec. drier, inlet pipe to 
exp. valve

7.5mm i.d.

A082P6078F

F

Evaporator to expansion valve

13.5mm i.d.

A082P6080F

    

Lotus Service Notes                                 Section PL

Page 15

PL.6 - REFRIGERANT OIL

The internal working parts of the compressor are lubricated by refrigerant oil.  This is a special type of oil

which has an affinity with the refrigerant, such that a proportion of the oil circulates with the refrigerant, around
the whole system.  Under normal operating conditions, the oil never needs changing or replenishing, and if the
correct procedure for system depressurisation and re-charging is followed, minimal oil will be lost from the
system during these operations.  If, however, the system suffers a major leak or sudden de-pressurisation,
most of the oil held in suspension will be lost as the refrigerant escapes, necessitating the addition of a speci-
fied quantity of oil to the compressor on re-assembly (see section PL.7).

If a refrigeration component is to be replaced, the removed item will contain a certain amount of oil, and

a corresponding amount of new oil must be added to the system on re-assembly:
Condenser;

30 cm³

Evaporator;

30 cm³

Any major pipe or hose;

10 cm³

Receiver-drier;

30 cm³

Approved Oils
Use only Denso ND-OIL 8 low viscosity (ISO46) PAG oil or equivalent (Sanden SP10; Four Seasons 59007).

Refrigerant oil absorbs water and should not be exposed to the atmosphere for any longer than is strictly

necessary to perform the operation.  Never return decanted oil back into the storage container.

    

Lotus Service Notes                                 Section PL

Page 16

PL.7 - COMPRESSOR

The a.c. compressor is mounted on the left hand side of the cylinder block, beneath the alternator, and is

accessible from below.

A single multi-rib serpentine type belt is used to transmit drive from the crankshaft to the water pump,

alternator and a.c. compressor, with a slave pulley fitted in place of the power steering pump used in other
applications.  A hydraulically damped, spring loaded tensioner arm applies tension to the back of the belt, and
is maintenance free.  The belt itself should be inspected for condition at each service interval, and if it exhibits
any evidence of physical damage, cracking, fraying, perishing, abrasion or contamination, it should be re-
placed.  In the case of oil or coolant contamination, the cause must be identified and rectified, and each of the
pulleys must be thoroughly degreased before the new belt is fitted.

For further details, refer to section CH in the Engine Repair Manual, but note that only a six-point socket

should be used on the cast hexagonal boss on the tensioner arm.  The manufacturing draft angle on this
component may result in damage being caused by a twelve point socket.

Compressor Removal
1.

Remove the compressor drive belt by applying a six-sided socket to the cast boss on the tensioner arm
to relieve the tension, and slip the belt off the compressor pulley.

2.

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

2.

Remove the engine bay undertray.

3.

From beneath the car, release the suction and discharge pipes from the compressor and immediately cap
the pipes and compressor ports to prevent ingress of dirt and moisture.

4.

Disconnect the compressor clutch harness.

5.

Release the three compressor fixing bolts, and remove the compressor from the engine.  Retain the
compressor for oil quantity measurement if a new unit is to be fitted.

Oil Quantity Adjustment Prior to Compressor Refitment
Refitting Existing Compressor
i)

If the existing compressor is to be refitted after normal refrigerant recovery has been performed, a quan-
tity of oil equivalent to that recovered must be added to that already held in the compressor.

ii)

If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost.  Drain the remaining oil from the compressor by removing the drain
plug and rotating the clutch plate.  Add 60 cm³ of new refrigerant oil (see above) to the compressor before
refitment.

Fitting New Compressor

New compressors are sealed and pressurised with nitrogen gas.  The sealing caps should be removed

only immediately prior to compressor fitment, at which time the gas pressure should be heard to escape as a
cap is slowly released.  New compressors are supplied with an oil fill of 60 cm³.
iii)

If normal refrigerant recovery has been performed, the new compressor oil should be drained off, and the

required oil quantity in the new compressor calculated and added:

-

Drain and measure the oil quantity in the OLD compressor by removing the drain plug and rotating
the clutch plate. Quantity = X cm³

-

Oil quantity to be added to new compressor = X + 10 cm³

iv)

If the system has suffered a rapid discharge, caused for example by accident damage, most of the
refrigerant oil will have been lost.  In this case, drain the new compressor of oil and refill with 60 cm³.

    

Lotus Service Notes                                 Section PL

Page 17

Compressor Fitment
1.

Fit the compressor to the engine and secure with the three M8 bolts; Tighten to 25 Nm (18 lbf.ft).  Using
a six-sided socket on the tensioner arm, fit the drive belt onto the compressor pulley.

2.

Using new 'O' rings lubricated with an approved refrigerant oil, fit the two refrigerant pipes to the compres-
sor and tighten the fixing screws to 10 Nm (7 lbf.ft).

3.

Connect the compressor clutch harness.

4.

Recharge the system with R134a refrigerant.

Compressor
harness
connector

High pressure
outlet connection

Low pressure
suction inlet
connection

        p113

Compressor fixing bolts