Lotus Eleven/Elise/Exige. Manual - part 81

Page 19

 

 

Lotus Service Notes   

 

 

    Section MP

    Positive post on bulkhead

Chassis                                                  Chassis front

earth      To ECU                                          earth point

stud      plate      To transmission           Positive binding

                housing               post on scuttle                           

                                                     

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

         

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

    m191b

                             

              Positive binding post

              on scuttle

Chassis front

earthing point

                                            Starter 

                                            solenoid 

                                                    Battery 

                                                    negative   Battery

                                                            positive

                             

                               

         

 

 

 

 

 

 

 

 

 

 

 

 

 

 

    m191b

                                          Chassis rear earth point

Battery cables; positive & negative posts

Page 20

 

 

Lotus Service Notes   

 

 

    Section MP

MP.8 - WIPER MECHANISM

The windscreen wiper mechanism comprises a uni-directional motor with an external rotary link, a con-

necting rod, and a pair of actuating links which join the connecting rod to the arms of the wiper spindle.  This 

mechanism provides the wiper with a motion which is slowed at each end of its travel in order to ease the 

inertia loads during direction changes, to the benefit of refinement and durability.  The motor and wheelbox are 

mounted on a single fabricated steel bracket which is bolted to the windscreen scuttle panel.

To remove the wiper mechanism:

1.  Remove the front clamshell (see sub-section BP.5).

2.  Remove the wiper motor protective cover by releasing the two screws into the windscreen buttress, and 

the patch of adhesive between the inboard end and the screen gutter.  Disconnect the harness plug from 

the motor.  Disconnect the washer tubing.

3.  Remove the wiper arm from the spindle, and the spindle rubber surround.

  

4.  Release the three screws securing the motor mounting bracket to the windscreen frame - one at each side 

of the spindle, one at the motor end, and withdraw the complete mechanism from the car.

5.  If the motor is separated from the mechanism, the position of the rotary link should be marked against 

the motor shaft for reference when re-fitting.  The motor should be in the 'park' position before fitting, and 

the mechanism at full travel so that the rotary link and connecting rod are aligned in the fully extended 

position.

      Spindle rubber surround

                                            Wiper arm

Wiper motor 

mounting bracket

Clamshell

mounting 

plinth

                                                        Bracket fixing

                              bolt

Bracket 

fixing

bolts

                                                      Wiper motor assembly

 

 

 

 

 

 

 

 

 

 

 

        

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

                   m208

Page 21

 

 

Lotus Service Notes   

 

 

    Section MP

6.  Re-assemble in the reverse order to removal, torque tightening the bracket bolts to 20 Nm.

MP.9 - HARNESS ROUTING 

The main harness runs from the main fusebox/relay station at the passenger side of the front services 

compartment, and divides into three branches; one running forwards across the front of the chassis well to feed

the interior fan motor, heater/a.c. functions, radiator fans and ABS controller, and then round the front of the 

crash structure to supply the horn and front lights.  A second branch connects to the radiator fans/a.c. control 

module mounted on the passenger side wheelarch liner.  The third brance runs rearwards through the scuttle 

where it divides again to run across the dash top, picking up on the positive post, and supplying the instrument 

pack and switchgear.  The harness then runs along the cockpit centre tunnel to the rear of the cabin, over the 

top of the fuel tank bay, and through a grommet at the left hand rear corner of the cabin.

At the left hand front corner of the engine bay, one branch continues rearwards through a rear clamshell 

grommet to connect with the rear lighting harness routed inside the clamshell.  Another branch runs across the 

engine bay/cabin bulkhead to the multi-function relay module and engine ECU.  The engine harness connects 

to the ECU on the bulkhead.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

      

RHD Shown

(LHD symmetrically

opposite)

Wiper linkage 

in full travel 

position                              

         

 

 

 

 

 

 

 

 

 

 

 

               m209

Front section fixed      Routed along dash top  

to crash structure                                  Engine harness

                                                          Wheel speed

                                                          sensor

Fusebox &

rad. fan/a.c.               Routed along

module                  centre tunnel                                  Rear 

                                                                  harness

              Positive              Engine ECU

              post                                                     

 

 

          

 

                  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 pl1701mt

Page 22

 

 

Lotus Service Notes   

 

 

    Section MP

  Dip beam lamp

  Main beam

  lamp

                        Sidelamp bulb

                               

ohs107

MP.10 - FRONT LAMP ASSEMBLIES

Headlamp Units - Prior '07 M.Y.

The front clamshell incorporates, at each side, a headlamp housing, in each of which are mounted a halo-

gen projector type dip beam lamp (upper), and a halogen main beam lamp (lower), which also incorporates the 

sidelamp bulb.  A moulded plastic mask and clear acrylic cover are bonded together and are fitted over each 

headlamp housing, with a rubber surround finisher, with the unit retained by three slotted thumbscrews acces-

sible from within the front wheelarch.  For access to the headlamps, release the three socket head screws and 

withdraw the headlamp cover assembly.

Headlamp bulbs may be replaced after disconnecting the cables (Dip; blue/yellow, black. Main; blue/

black, black) and releasing the spring clip.  Both the 55W H1 dip beam bulb, and the 55W H7 main beam bulb 

incorporate orientation features which must be correctly located on re-fitting.  The holder for the T4W bayonet 

fitting sidelamp bulb may be twisted to release from the main beam headlamp.  

If the car is to be used temporarily in an opposite drive hand territory, a masking lever incorporated in each 

dip beam headlamp should be moved to provide a horizontal cut off and prevent dazzle.

Headlamp Beam Alignment

1.  Using beam setting equipment compatible with ECE Regulation No.48 for 76/756/EEC, position the machine 

between 300 and 700mm in front of the LH headlamp, and parallel with the two headlamp units using the 

sight bar or similar device dependent on the machine design, to ensure cross car match.  Use the guides 

provided on the machine to ensure the correct height and lateral setting.  

2.  Switch on the headlamp dip beams (uppermost lamps), and check the lateral beam alignment. The ‘knee

point’ of the beam cut off line must lie within a tolerance of 2% to the passenger side, and 0%.

Check the vertical alignment of the dip beam which must lie within a tolerance of -0.5% and -2%.

3.  If adjustment is required, from within each front wheelarch, using a 5mm hexagonal key, remove the three 

socket head screws securing the headlamp cover/masks, and withdraw the covers complete with rubber 

seal.

4.  To adjust the dip beam laterally, adjust the dome headed screw at the upper inboard side of the dip beam 

(uppermost) lamp, accessed from the front of the lamp.  Turn clockwise to adjust the beam to the right.  

Optimum setting is 0%.

 

To adjust the vertical aim of the dip beam, adjust the dome headed screw at the lower outboard side of 

the lamp, accessed from the front. Turn clockwise to raise the beam. Optimum setting is -1.5%.

5.  Repeat for the RH lamp.

6.  Centralise the machine on the LH main beam (lowermost) lamp, and switch on the main beams.  Check the 

main beam alignment which should be centralised with the marker dot on the machine screen or slightly 

below the horizontal. Optimum setting is 0%.

 

- To adjust the main beam laterally, adjust the dome headed screw at the upper inboard side of the lamp, 

   

HEADLAMP COVER UNIT SOCKET BOLTS

   

ohs105a