Lotus Evora. Manual - part 91

 

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Lotus Evora. Manual - part 91

 

 

 

 

Lotus Service Notes   

 

 

   Section WF

tensioners.

In case of a required deployment, timely switching of the activation current for the deployment loops.

Detection of electrical system faults which may influence the readiness of the system to deploy, or increase

the probability of an inadvertent deployment by:

 

- continuous electrical monitoring of all deployment circuits (without any effect on the readiness of the 

system);

 

- continuous monitoring of the supply voltage and the lamp circuitry (dependent on lamp driver activation 

status);

 

- SDM self test;

 

- activation of a tell tale lamp in case of a detected system fault.

Fault storage and 'Crashrecording' within EEPROM ('crashrecording': recording of system parameters

{e.g. fault status in deployment events}).

Diagnostic communication using an ISO9141 protocol.

Frontal Impact Sensing and Deployment

The SDM and the two forward crash sensors contain accelerometers which provide a nearly linear propor-

tional electrical representation of the acceleration experienced by the vehicle along the longitudinal axis.  This 

signal is amplified and filtered to reduce unwanted electronic noise and to compensate for offset drifts.  The 

filtered signal is then digitized to provide an input for evaluation by the crash algorithm.  As soon as the crash 

algorithm detects that pre-defined thresholds have been exceeded, the SDM activates both airbags in either 

stage 1 or stage 2 mode, and both front seat belt pre-tensioners.

To enhance system reliability under normal driving conditions, an additional electromechanical 'safing' 

sensor is included within the SDM to ensure that the SRS is armed only when significant deceleration occurs.  

In order to protect against undesired deployments in case of severe EMI, humidity or accelerometer fault, the 

deceleration condition monitoring by the safing sensor occurs in addition to, and independent of, the crash 

algorithm.

Note that neither the seat belt pre-tensioners nor the airbags will be activated by the SDM as long as the 

diagnostic mode is active.

Fault Display

The following conditions lead to a fault display in the form of continuous illumination of the airbag tell 

tale:

One or more trouble codes requiring tell tale lamp activation in the 'historic' and 'present' condition are

stored in the SDM's EEPROM.

One or more trouble codes requiring tell tale lamp activation in the 'present' condition only are stored in

the SDM's EEPROM, the condition of which is, or has been, 'present' in the current operating cycle.  For 

all faults requiring four consecutive incidents for a trouble code to be set, the 'present' condition and fault 

display will be activated already after two consecutive events if the related trouble code has already been 

stored in a previous operating cycle.

Faults concerning the voltage supply (overvoltage/undervoltage) will lead to tell tale activation only until

the regular voltage range has been reached again (turn-off delay max. 5s after return from undervoltage 

and max. 20s after return from overvoltage).  There are no related trouble codes.

The airbag tell tale will not be activated due to SRS warning lamp related faults.

The tell tale will be activated immediately after entering the diagnostic mode, or on deployment of the

SRS.

 

Excluding the exceptions stated above, it is not possible to switch off the tell tale other than by resetting 

the fault codes stored in the EEPROM.  This is not possible after an airbag deployment - the SDM must be 

renewed.

The following delays apply for the detection and display of faults.  The delays apply from the extinguishing 

of the tell tale, following the ignition switch on bulb check period:

1 to 5 secs    - for external deployment circuit faults and overvoltage supply.

12 to 20 secs  - for undervoltage supply.

up to 15 secs  - for SDM internal faults.

 

 

 

Lotus Service Notes   

 

 

   Section WF

The tell tale will be activated without SDM intervention in the following situations:

the minimum voltage of 8.0 V has not been exceeded after switching on the ignition.

the energy reserve (in SDM) has run low, which may be caused by supply voltages below 7.8 V.

the watchdog has interfered.

  A trouble code readout using tell tale blink codes is not implemented.

Power Supply & Grounding

The nominal supply voltage of +12 volts is derived from terminal 5 when the ignition is switched on.  The 

SDM internal ground (terminal 7) must be securely connected to the vehicle chassis ground.  To provide redun-

dant grounding, the SDM housing is internally connected to the ground connector pin.

Supply Voltage Range

The SDM is designed to operate within the following voltage ranges:

System fault detection, SDM self test: min. 8.0 V; max. 16.0 V

Below 10.0 V system readiness may be delayed by 3 s.

Below 9.0 V system readiness may be delayed by 10 s.

System fault detection and SDM self test are reduced as long as an undervoltage condition is detected, which 

could already apply for supply voltages below 10.5 V.

Activation of airbags: min. 8.0 V; max. 16.0 V.

Activation of seat belt pre-tensioners: min. 10.0 V; max. 16.0 V. 

Energy Reserve

Energy reserve capacitors within the SDM are provided to allow SRS deployment if the vehicle battery 

power supply is interrupted during the time of vehicle impact.  The capacitors provide full support of the accel-

eration sensing and airbag initiation capability for a minimum of 150 ms after a loss of external power supply, 

provided that before the loss, the SDM had been supplied with:

at least 10.0 V for at least 10 s; or

at least 9.0 V for at least 13 s; or 

at least 8.0 V for at least 20 s.

The capacitors will be discharged down to a point where no initiation of airbags is possible within a max. 

of 20 s after removal of the power supply.

WF.8 - SENSOR & DIAGNOSTIC MODULE (SDM)

To Replace SDM

WARNING: The SDM must be replaced after SRS deployment.  Do not attempt to repair or reuse.

 

The SDM is mounted in an alloy box bolted to the centre underside of the scuttle beam.

1.  Follow the safety procedure detailed in sub-section WF.6 to turn off the ignition, disconnect the battery 

and unplug the rotary connector.

2.  From the footwells, release the 8 setscrews securing the SDM mounting box to the scuttle.  Release the 

three screws securing the SDM to the box and unplug the two harness connectors.

Refitment of the SDM is a reversal of the removal procedure, torque tightening the fixing screws for SDM 

and mounting box to 9 Nm.

 

 

Lotus Service Notes   

 

 

   Section WF

WF.9 - DRIVER AIRBAG MODULE

WARNING:  Safety precautions must be observed when handling a deployed airbag.  After deployment, 

the airbag surface may contain a white packing powder used to ease deployment.  Always wear gloves 

and safety glasses when handling a deployed inflator module, and wash your hands with a mild soap 

and water afterwards.

The driver's airbag (or inflator module) is housed in the hub of the steering wheel, beneath a moulded trim 

cover designed to hinge open in the event of deployment.   The module comprises:

an inflatable fabric bag;

an inflator (canister of gas generating material)

an initiator (or 'squib')

The complete module also serves as a horn operating pad, such that pressing anywhere on the steering 

wheel centre trim will operate the horns.  The module is spring mounted to a baseplate secured to the steering 

wheel hub, the baseplate carrying 4 earthed electrical contacts which correspond with 4 opposing contacts 

supplied with 12 volts and mounted on the module itself.  Closing any of the contacts will ground the circuit 

and sound the horns.

When the vehicle suffers a forward deceleration of sufficient magnitude to close both the safing sensor 

and the integrated accelerometer within the SDM or one of the two forward crash sensors, current flows through 

the stage 1 or stage 2 deployment loop of both the driver and passenger airbag module initiators and ignites 

the gas generating material.  Each bag inflates in a fraction of a second, the driver's bag bursting open the 

steering wheel centre trim cover, and then deflates via vents in the bag, with the whole cycle taking less than 

one second.  The airbag is designed for a single deployment, and must then be renewed.

In order to help prevent unwanted deployment of the driver's airbag when servicing the steering column 

or other SRS components, a shorting bar is incorporated into each of the two connector sockets on the rotary 

connector (one connector for each airbag stage).  The shorting bar operates when the connector is unplugged, 

to short across the feed and return connections to the airbag.  Thus, if a positive feed, or earth is inadvertently 

applied to the connector terminals, both sides of the inflator module will be subject to the same electrical po-

tential, and no deployment will occur.  The same feature is included in the airbag module connector sockets.  

To replace driver's airbag

WARNING:  The following procedures must be followed in the order listed to temporarily disable the 

airbag system whilst working in the immediate vicinity of an airbag.  Failure to follow this procedure 

could cause unintended airbag deployment, resulting in personal injury and unnecessary airbag sys-

tem repairs.

1.  Follow the safety procedure detailed in sub-section WF.6 to turn off the ignition, disconnect the battery 

and unplug the rotary connector.

2.  On the reverse side of the steering wheel, release the two Torx head screws, accessible via holes in the 

plastic shroud around the steering wheel hub.  Withdraw the airbag module and disconnect the two airbag 

harness connectors and the two horn leads.

WARNING:  When carrying a live airbag module, make sure the bag and trim cover are pointed away 

from you.  In case of an accidental deployment, the bag will then deploy with minimal chance of injury.  

When placing a live airbag module on a bench or other surface, always face the bag and trim cover 

upwards, away from the surface.  This is necessary so that a free space is provided to allow the airbag 

to expand in the unlikely event of accidental deployment.

3.  If a driver's airbag is deployed, refer to steering sub-section HI.5 to determine whether the steering column 

telescoping mechanism has been activated, and if necessary, renew the column assembly.

4.  Mate the two harnesss connectors to the new airbag module sockets, matching the colour coding, and 

connect the two horn leads.  Locate the module into the steering wheel and retain with the two Torx head 

retaining screws, tightening to 7 Nm.

 

 

Lotus Service Notes   

 

 

   Section WF

5.  When all service work is complete, connect the harness plugs to the rotary connector sockets and refit 

the column shrouds.  Reconnect the battery, turn on the ignition and check that the airbag tell tale lights 

for a few seconds and then goes out.

WF.10 - ROTARY CONNECTOR

WARNING:  The rotary connector MUST be replaced after SRS deployment even if there is no visible 

damage.

The rotary connector is a device which fits between the steering wheel and column, and allows the steering 

wheel to turn whilst maintaining electrical continuity to the airbag module and horn buttons.  The assembly con-

sists of an annular housing fitted over the top end of the steering column, and containing a coil of wires providing 

feed and return circuits for the first and second stage airbag initiators, horn buttons and cruise controls.

The steering column side of the device is fitted with a connector block into which is plugged a branch of 

the main vehicle harness.  The steering wheel side of the device has a divided connector block for the cruise 

control jump harness, and the airbag/horn jump harness.  The coil housing is constructed in two parts, with the 

outer part fixed to the outer (stationary) column, and the inner part keyed to the steering wheel.  The two parts 

of the coil housing slide inside of each other in such a way as to allow the steering wheel to be rotated through 

its full travel, lock to lock, whilst maintaining an unbroken feed to each of the circuits in the steering wheel hub, 

via the continuous wires in the coils.

In order to help prevent unwanted deployment of the air bag when servicing the steering column or other 

SIR components, a shorting bar is incorporated into the rotary connector column side connector socket.  This 

shorting bar operates when the connector is unplugged, to short across the feed and return connections to the 

inflator module. Thus, if a positive feed, or earth is inadvertently applied to the connector terminals, both sides 

of the inflator module will be subject to the same potential, and no deployment will occur.

When servicing the rotary connector, it is most important that the correct orientation of the connector is 

maintained on refitment, or the connector will run out of travel and be broken.

To replace the rotary connector

1.  Remove the airbag module from the steering wheel (see sub-section WF.8).

2.  Disconnect the cruise control harness plug.

3.  Ensure the wheels are pointing straight ahead, match mark the wheel to the column, and remove the 

steering wheel retaining bolt.  Note that the wheel is located on a steep angle hexagonal taper on the 

column.  

 

CAUTION:  If excessive force is applied to either the steering wheel or column, the break-out in-

serts securing the column to the fascia bracket may be disturbed, necessitating replacement of 

the complete column.  If necessary, use an appropriate puller.

4.  Unplug the harness from the two column lever switches and unclip each switch from the carrier.

5.  Unplug the harness from the column side of the rotary connector, unclip the carrier from the outer column, 

and slide the the rotary connector from the steering column.

6.  Refit in reverse order to removal, but before fitting the steering wheel, it is essential to centralise the rotary 

connector, or the unit will be broken when lock is applied.  Turn the connector fully clockwise until it tightens, 

and then turn back just over two turns until the red marker appears in the square window.  Note that this 

instruction is printed on the rotary connector.  Ensure the road wheels are pointing straight ahead and fit 

the steering wheel with the match marks aligned.  Tighten the steering wheel retaining bolt to 50 Nm.

 

When fitting the jump harness for the cruise controls, ensure the cable is routed through the channel 

provided in the steering wheel carrier.

7.  After re-assembly, check that the airbag tell tale lights for a few seconds with ignition, and then goes 

out.

 

 

 

 

 

 

 

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