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Lotus Evora. Manual - part 17

Lotus Service Notes

Section EJ

ENGINE – 2GR-FE ENGINE

01MEG11Y

285EG01

EG-68

2GR-FE ENGINE

�

DESCRIPTION

The 2GR-FE engine on the ’06 RAV4 is a newly developed, V6 3.5-liter, 24-valve DOHC engine. This engine
uses the Dual VVT-i (Variable Valve Timing-intelligent) system, DIS (Direct Ignition System), ACIS
(Acoustic Control Induction System), and ETCS-i (Electronic Throttle Control System-intelligent). These
control functions achieve improved engine performance, fuel economy, and reduced exhaust emissions.

ENGINE

– 2GR-FE

ENGINE

01MEG1

285EG01

EG-68

2GR-FE

ENGINE

�DESCRIPTION

The 2GR-FE

engine on

the ’06 RA

V4 is a newly

developed,

V6 3.5-liter

, 24-valve

DOHC engine.

This engine

uses the

Dual VVT

-i (Variable

Valve T

iming-intelligent)

system,

DIS (Direct

Ignition

System),

ACIS

(Acoustic

Control

Induction

System),

and ETCS-i

(Electronic

Throttle

Control

System-intelligent).

These

control functions

achieve

improved

engine performance,

fuel economy

, and reduced

exhaust

emissions.

EJ.1 - INTRODUCTION

General Layout

Throttle body

Variable Valve

Timing (VVT)

sprocket hub

Coolant outlet

housing

Water pump

Oil pump

Oil filter

Acoustic Control

Induction System

(ACIS) butterfly

valve

Hydraulic

tappet

finger

post

Primary catalytic

converter

Cross bolted main

bearing cap

Cartridge oil filter

e237

Lotus Service Notes

Section EJ

EJ.1 - INTRODUCTION

Terminology

The powertrain of the Eagle is mounted transversely, with the crankshaft of the engine running parallel

to the rear axle line. The front of the engine is to the right of the engine bay and the rear to the left. When

refering to powertrain components, this logic will be used, e.g. the left hand side of the engine is towards the

front of the engine bay.

General Description

The 2GR-FE engine fitted to the Eagle is supplied by Toyota, and comprises a 3.5 litre 60° V6 unit mounted

transversely (front of the engine towards the right) in the 'mid engine' position between the cabin and rear wheel

axis. The cylinder block/crankcase and cylinder heads are cast in aluminium alloy with the block featuring an

open deck construction and integral cast-in iron liners. The forged steel crankshaft runs in 4 main bearings,

with each of the 3 crankpins accommodating two forged steel connecting rods, those of the RH cylinder bank

foremost. Each cylinder head houses twin overhead camshafts operating two inlet and two exhaust valves

per cylinder, via roller followers mounted in steel fingers, the pivot posts of which provide for zero valve clear-

ances by hydraulic means. The bifurcated ports are arranged with the inlets positioned inside the 'V' and the

exhaust ports outboard. The inlet camshafts are driven by a single roller chain from the crankshaft nose, with

each exhaust cam driven by a short, link chain from its neighbouring inlet camshaft.

In order to optimise power, economy, emissions and noise, the engine control system includes; dual VVT-i

(Variable Valve Timing - intelligent) to provide phase shifting of both inlet and exhaust valve timing; ACIS (Acous-

tic Control Induction System) to vary the effective intake tract length to the benefit of both high and low speed

power output; ETCS - i (Electronic Throttle Control System - intelligent) to facilitate traction control, skid control

and cruise control; AICS (Air Intake Control System) to reduce intake noise in the low to mid range of engine

speed without sacrificing efficiency at high engine speed. The engine management system is programmed by

Lotus using the T4e controller.

The engine is mated to a type EA60 6-speed manual transmission supplied by Toyota, and installed in

the engine bay with transmission on the left hand side. Primary mountings for the power unit pick up off the

front of the engine and to the top rear of the transmission case, and connect with the suspension towers on the

rear subframe via voided elastic isolators. Secondary engine steady mountings are used to control powertrain

roll under drive torque and inertia effects, and are fitted low down on either side of the block, attaching to the

chassis rear crossmember and to the subframe via elastic isolators.

EJ.2 - AIR CLEANER ELEMENT INSPECTION/REPLACEMENT

To inspect the air cleaner element, the airbox cover complete with resonance chamber, may be removed

from the throttle body and air cleaner base unit without disturbing the clamshell.

1. Remove the LHR wheel.

2. Release the clamp securing the convoluted intake hose from the airbox to the throttle body.

3. Release the rear bank cam cover breather hose from the convoluted intake hose.

4. Release two vacuum hoses from the airbox reservoir, one from an intake tract), the other to the intake flap

valve solenoid.

5. Unplug the harness connector from the airflow sensor.

6. From within the LHR wheelarch, remove the access panel in the wheelarch liner and release the two

overcentre clips on the airbox. Unhook the airbox cover from the base and withdraw. Thoroughly clean

the cover.

7. Clean all around the airbox base before removing the cleaner element, taking care to avoid contaminating

the base unit with dust or dirt. Fit the new element into the base, and refit the cleaned cover, ensuring

that the moulded tongues are fully engaged in the base unit. Fasten the two overcentre clips, and check

Lotus Service Notes

Section EJ

again for correct mating.

8. Continue re-assembly in reverse order to removal.

EJ.3 - ENGINE OIL & FILTER CHANGE

The engine oil hex. head drain plug is located in the base of the pressed steel sump

Remove the plug to

drain the sump immediately after a run when the oil is warm and the impurities are still held in suspension.

WARNING

•

Engine oil is hazardous to your health and may be fatal if swallowed.

•

Take all suitable precautions to guard against scalding from the hot oil.

•

Prolonged and repeated contact with used engine oil may cause serious skin disorders, including dermatitis

and cancer.

•

Use protective gloves to avoid contact with skin as far as possible and wash skin thoroughly after

any contact.

•

Keep out of reach of children.

Allow the oil to drain completely before cleaning the drain plug, fitting a new sealing ring, and tightening

securely. Refill with the recommended lubricant (see section OK) via the oil filler on the camshaft cover, to the

top mark on the dipstick, allowing several minutes for the oil to drain through to the sump before checking the

level. Take care not to overfill. Refit the oil filler cap securely, and check the oil level again when the engine

is fully warm.

Oil Filter

The cartridge type oil filter is mounted at the right hand front of the engine, and is accessible only from

beneath. The filter should be renewed along with the engine oil, at intervals specified in the Maintenance

Schedule.

The oil filter housing incorporates a drain plug to minimise potential oil spillage;

Unscrew the drain plug (square socket) from the filter housing cap and collect the small amount of oil

released.

Connect a length of 15mm i.d. hose to the drain pipe supplied with the new filter. Insert the pipe into the

base of the filter housing with the ‘O’ ring on the top side of the tube flange, and push upwards until it clicks

into position and opens the spring loaded drain valve. Collect the draining oil.

Remove the drain tube by pulling sideways and down.

Using special tool T000T1511, unscrew the cap from the filter housing. Discard the filter element and filter

cap ‘O’ ring.

Thoroughly clean the filter cap, filter housing and drain plug.

Fit the new ‘O’ ring supplied with the new filter element into the cap groove, and lubricate with engine oil.

Fit the new filter element into the cap, and install the filter and cap into the housing, ensuring that the ‘O’

Lotus Service Notes

Section EJ

ring does not become displaced.

Using special tool T000T1511, torque tighten the cap to 25 Nm. Check that there is no clearance between

cap and housing.

Lubricate the small ‘O’ ring supplied with the new filter with engine oil, and fit into the groove in the filter

housing. Fit the filter drain plug and tighten to 13 Nm.

Check the oil level (see above) before starting the engine and restricting to idle speed until the oil pressure

tell tale is extinguished. Check for oil leaks with the engine running. Stop the engine when fully warm

and re-check oil level.

EJ.4 - AUXILIARY DRIVE BELT

A single serpentine multi-rib auxiliary belt is used to transfer drive from the crankshaft nose pulley to the

power steering pump, water pump, alternator and a.c. compressor. An automatic type belt tensioner is provided

in the form of an idler pulley mounted on a spring loaded arm. At each service interval, the whole length of belt,

on both the inside and outside surfaces, should be examined for any evidence of perishing,cracking, chafing,

splitting, tearing, delamination, contamination or other indications of undue wear or deterioration. In any cases

of doubt, the belt should be renewed.

Auxiliary Belt Replacement

Remove the RH rear wheel and wheelarch liner.

If the original belt is to be refitted (renewal is recommended), mark the direction of rotation on the belt

before removal.

Using a 14 mm hexagonal socket and long bar, rotate the tensioner pulley counterclockwise to relieve the

tension on the belt.

Align the hole in the arm with the corresponding drilling in the baseplate and insert a 5mm rod or hex. key

to hold the tensioner in the released position.

Slide the belt off the pulleys.

When reinstalling the belt, retain the original direction of rotation, and ensure that the belt ribs are correctly

located on each drive pulley, before finally fitting over the tensioner pulley. Rotate the tensioner counterclock-

wise to relieve tension and remove the locking pin.

EJ.5 - ENGINE REMOVAL/REPLACEMENT

The engine and/or transmission can be removed only as a combined unit, and should be lifted out from

above after removing the rear clamshell:

1. Preparation: Remove both rear wheels, the diffuser and engine undertray. Remove the rear clamshell

(see sub-section BV.6).

2. Drain fluids: Drain the transmission oil and the cooling system. De-pressurise fuel system (see sub-section

LN.3). Recover refrigerant gas.

3. Driveshafts and hub carriers:

At each side:

- Remove the rear brake calliper and support aside without straining the hydraulic hose.

- Disconnect the parking brake cable from the brake backplate.

- Disconnect the wheel speed sensor cable.

- On the RH driveshaft, release the two bolts securing the extension shaft bearing to the engine mounted

bracket.

- Release the fixings securing the top and bottom wishbones and toe-link to the hub carrier.

- Withdraw the complete RH hub carrier and driveshaft assembly, taking care not to damage the trans-

mission output shaft oil seal.

- The left hand driveshaft is retained in the transmission by a round section circlip. Use a suitable slide

hammer with a forked adaptor or use pry bar to apply a shock force to the body of the inboard CV joint

to release the driveshaft. DO NOT apply a pulling or extension force to the driveshaft assembly, or the

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