Lotus Eleven/Elise/Exige. Manual - part 114

    

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

Compressor 2ZZ & 1ZZ Powertrain;    60 cm³ (See additional information in section PL.7)
Compressor 1ZR Powertrain;             95 cm³  (See additional information in section PL.7)

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.

Updated 9th June 2010

    

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. For 2ZZ and 1ZZ powertrains add 60 cm³ of new refrigerant oil for 1ZR
powertrains add 95 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 (2ZZ & 1ZR) and 95 cm³ (1ZR).
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.

Updated 9th June 2010

    

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

Note

The 1ZR-FAE engine used in the 1.6 litre Elise, is a variable displacement compressor, instead of the

cycling clutch type used on the 1ZZ and 2ZZ engines.  A safety feature in the pulley hub allows the pulley drive
to shear in the event of compressor seizure, without jeopardising other ancillaries.

    

Lotus Service Notes                                 Section PL

Page 18

PL.8 - CONDENSER

The engine cooling radiator, a.c. condenser and cooling fans are secured together as a package and are

mounted horizontally, with fans lowermost, on top of the crash structure.  The all aluminium condenser is of
parallel flow construction, with tanks at each side which direct the refrigerant flow from the front inlet connec-
tion successively through 10, 7, 5 and 4 rows, before it emerges from the rear outlet union.  Bonded to the front
and rear of the condenser are steel channels which incorporate mounting brackets to attach the unit to the
lower flanges of the engine cooling radiator, and also to provide mountings for the two cooling fans.

For access to the condenser or cooling fans, the front clamshell must be removed followed by the radiator

mounting panel with the complete cooling pack.

1.

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

2.

Remove the two air deflector/water shields.

3.

Drain the coolant and disconnect the feed and return hoses from the radiator.

4.

Unplug the fan harness connector(s).

5.

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

6.

Using two spanners on each connection to avoid twisting the union, release the two refrigerant pipes from
the condenser and immediately cap both the pipes and the condenser unions to prevent the ingress of dirt
and moisture.

Engine cooling radiator

Front spreader plate

Rear
mounting

Front mounting

bracket

bracket

Radiator

a.c. condenser

mounting
panel

Cooling fan

        p106