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Lotus Evora. Manual - part 83

Lotus Service Notes

Section PN

Compressor Fitment

1. Fit the compressor to the engine and secure with the three M8 bolts; Tighten to 25 Nm (18 lbf.ft).

2. Using new 'O' rings lubricated with mineral refrigerant oil, fit the two refrigerant pipes to the compressor

and tighten each clamp plate screw to 8 Nm.

3. Connect the compressor clutch harness.

4. Fit the auxiliary belt around the pulleys ensuring correct engagement of the ribs. Apply a counterclockwise

torque to the auxiliary belt tensioner and remove the locking pin.

5. Recharge the system with R134a refrigerant.

PN.8 - CONDENSER

The a.c. condenser, engine cooling radiator and cooling fans (in front to back order), are secured together

as a package and mounted between the front subframe longerons leaning forwards at an angle of 45°. The

package is flexibly mounted via grommets and spigots off the engine radiator, with the condenser rigidly fixed

to the front of the radiator by 4 setscrews. The inlet pipe to the top section of the divided RH tank and the outlet

pipe from the lower section of the RH tank extend to a joint plate accessible from above.

Removal of the condenser from below is possible without disturbing the engine radiator, and is facilitated

by removal of the front clamshell, but is also possible with this panel in situ, using access provided by the

headlamp apertures.

To Remove Condenser

1. Remove the RHF wheelarch liner and recover the refrigerant using equipment connected to the service

ports at the rear of the wheelarch.

3. Remove the front undertray and both headlamp assemblies (see sub-section BV.4).

4. Remove the radiator air intake duct lower section:

- Release the headlamp powerwash hose from its 'P' clips

- Remove both horns

- Release the ambient temperature sensor from the RH side

- Remove the 2 fixings securing the condenser to the radiator lower mounting brackets

- Remove the 2 edge clips at each side securing the lower duct to the upper duct, and withdraw the

lower section.

5. From the RH headlamp aperture, release the clamp plate securing the refrigerant pipes connection.

6. From each headlamp aperture, release the screw securing the top of the condenser to the radiator

bracket.

7. At each side, release the single screw securing the bottom of the condenser to the radiator bracket, and

withdraw the condenser.

8. Refit in reverse order to removal.

- If a new condenser is fitted, add 30 cm³ of approved refrigerant oil to the system.

- Use new 'O' rings on the pipe connections, and lubricate with refrigerant oil.

- Recharge the system with 0.625 kg of R134a.

Lotus Service Notes

Section PN

PN.9 - RECEIVER-DRIER

If the system has been open to atmosphere for any length of time, e.g. following accident damage or a

burst hose or damaged component, the receiver-drier unit must be renewed, and should be the last component

to be fitted, and uncapped only immediately prior to connection and recharging.

The receiver-drier is clamped to a mounting bracket fixed to the outside face of the front subframe RH

longeron, ahead of the front wheel, and is accessible from beneath with the front undertray removed. If the

receiver-drier is to be replaced, the refrigerant must first be recovered using suitable equipment connected to

the service ports at the rear of the RHF wheelarch.

- Cap all pipes and ports immediately after disconnection to prevent the ingress of dirt and moisture.

- When reconnecting the pipes, use new 'O' rings coated in an approved refrigerant oil, and tighten to

25 - 30 Nm.

- If a new receiver-drier is fitted, add 30 cm³ of approved refrigerant oil to the system.

- Recharge the system with 0.625 kg of R134a.

PN.10 - HEATER/EVAPORATOR/FAN (HVAC) UNIT

The HVAC unit comprises left and right hand plastic mouldings sandwiched together and containing a

pair of blower fans supplied from two intake sources, an a.c. evaporator, a heater matrix, and two electrically

controlled flaps; one for the fresh air intake and one for the heater matrix. The complete HVAC unit is mounted

between the chassis front bulkhead and subframe cross-member, with the steering rack beneath, and the

radiator air outlet duct ahead.

To Remove HVAC Unit

1. Remove the front undertray, front clamshell, radiator air outlet ducts and HVAC air inlet duct.

2. Remove the wiper motor mechanism from the windscreen surround.

3. Recover the refrigerant.

4. Remove the HVAC pollen filter intake moulding.

5. Unplug the fan harness connector block, and disconnect the heater flap and air inlet flap actuators.

6. Release the a.c. pipes clamp plate from the expansion valve, release the outlet pipe 'P' clip and secure

the pipe aside, with both pipe and expansion valve port capped. Remove the pipe between receiver-drier

and expansion valve, and cap all pipe ends and ports.

7. Remove the subframe crossmember. Remove:

- 2 bolts securing the top of the HVAC unit to the subframe crossmember;

- 2 bolts each side to top of longerons;

- 2 Torx head screws each side to top of longerons;

- 4 bolts each side securing the crossmember wall to the inboard side of the longeron;

- 3 bolts securing lower edge of wall to subframe lower crossmember.

Withdraw the crossmember/wall assembly.

8. From beneath, release the single bolt securing the HVAC unit to the chassis bulkhead, and the two bolts

joining the fan housing bracket to the lower crossmember bracket.

9. Withdraw the HVAC unit.

The expansion valve is fitted onto the evaporator inlet and outlet pipes, and its removal requires disas-

sembly of the HVAC unit. Determine the availability of the valve before embarking on such a task.

Lotus Service Notes

Section PN

Outlet to compresser

Inlet from receiver-drier

M6 clamp screw 'O' ring seal

Top clamp plate

M5 clamp screw (x2)

Expansion valve body

Lower clamp plate

(tapped) 'O' ring seal

Evaporator outlet pipe

Evaporator inlet pipe

p71

Refit the HVAC unit in reverse order to removal:

- If a new evaporator is fitted, add 30 cm³ of approved refrigerant oil to the system.

- Use new 'O' rings on the pipe connections, and lubricate with refrigerant oil.

- Recharge the system with 0.625 kg of R134a.

PN.11 - AIR DISTRIBUTION UNIT (ADU)

The airflow distribution unit is mounted on top of the chassis scuttle, sandwiched between the underside of

the fascia top/demist duct and the chassis. The unit comprises several plastic mouldings bonded and rivetted

together to contain the rotary distribution drum which controls the airflow to the windscreen, face level vents,

and footwells. The stepper motor for the drum is mounted on the left hand side of the unit.

To Remove the Air Distribution Unit

1. Remove the main fascia panel (see sub-section VE.8).

2. Remove the footwell duct between the side of the ADU and the passenger side scuttle aperture, by prising

away from its double sided tape.

3. Remove the 2 bolts securing the ADU integral rear bracket to the scuttle.

4. From within the footwell, release the single bolt within the scuttle top central reinforcement channel.

5. Withdraw the ADU and disconnect the drum actuator harness plug.

Lotus Service Notes

Section PN

PN.12 - REFRIGERANT PIPES

The main feed and return (high pressure liquid and low pressure suction) lines between the compressor,

condenser and expansion valve, take the form of aluminium pipes clamped along the outside of the chassis

RH siderail, such that removal of the body side panel is required for access to the pipes. Replacement of the

pipes is unlikely to be necessary other than as a result of accident damage, in which case the body sill will be

replaced in accordance with Service Notes sub-section BS.9.

Content .. 81 82 83 84 ..