SERVICE

NOTES

Section AA

Introduction
2004 Model Year Onwards
with 1ZZ/2ZZ/1ZR/2ZR Engine

Lotus Cars Ltd. Hethel, Norwich, Norfolk, NR14 8EZ, England.

Tel: +44 (0)1953 608000 Fax: +44 (0)1953 608300 www.Lotuscars.com

Part number A120T0327J © Lotus Cars Ltd. 2010

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 Lotus Service Notes Introduction Section AA

CONTENTS

ELISE & EXIGE; 2004 M.Y. ONWARDS; WITH 1ZZ/2ZZ/1ZR ENGINE

Section

Introduction AA

Technical Data - Engine TDP

- Vehicle TDQ

Chassis AH

Bodycare & Repair BQ

Body Fittings BR

Front Suspension CI

Rear Suspension DH

Engine & Engine Management - Lotus supplement EH

- Toyota 1ZZ/2ZZ repair manual *
* see separate manual E120T0327J
- Toyota 1ZR repair manual **
** see separate CD T000T1523F
Engine Management EMP

Transmission - Lotus supplement FJ

- Toyota C64/C56 repair manual #
# see separate manual E120T0327J
- Toyota EC60 repair manual ##
## see separate CD T000T1523F

Wheels & Tyres GH

Steering HG

Brakes JJ

Engine Cooling KH

Fuel System - Except North America LJ

- North America LK

Electrics MP

Circuit Diagrams: non - USA prior '06 MP14a
Circuit Diagrams: USA - prior '06 MP14b
Circuit Diagrams: '06 Onwards MP14c
Circuit Diagrams: '08 Onwards MP14d
Circuit Diagrams: '11 Onwards 1ZR Powertrain (Kelsey Hayes ABS) MP14e
Circuit Diagrams: '11 Onwards 2ZZ Powertrain MP14f
Circuit Diagrams: '11 Onwards 1ZR Powertrain (Bosch ABS) MP14g
Circuit Diagrams: '12 Onwards 1ZR & 2ZR Powertrain (VIN CHD10205 onwards) MP14g

Continued.....
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 Lotus Service Notes Introduction Section AA

Continued.

Section

Maintenance & Lubrication OI

Air Conditioning, Heating & Ventilation PL

Clutch QH

Supplementary Restraint System - SRS (Airbags) WD

Supplement - Exige Supercharged (S/C) Exige S/C

Supplement - 2-Eleven 2-Eleven

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 Lotus Service Notes Introduction Section AA

INTRODUCTION

SECTION AA

Sub-Section Page

Please Read Terms Before Using This Publication 5

How To Use This Manual 5

Vehicle Identification (V.I.N.) & Engine Number 6

V.I.N. Decoder 7

Model History Milestones 8

Jacking & Lifting Points AA.1 14

Engine Bay Undertray & Diffuser AA.2 15

Front Undershield AA.3 16

Vehicle Recovery AA.4 17

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 Lotus Service Notes Introduction Section AA

Publication Part Number A120T0327J © Lotus Cars Ltd. July 2012

PLEASE READ THESE TERMS CAREFULLY BEFORE USING THIS PUBLICATION

This publication has been designed for use by Lotus Dealers familiar with general workshop safety proce-
dures and practices. Take all appropriate action to guard against injury to persons or damage to property.

It is also assumed that any other persons using this publication has the relevant technical experience to
utilize a workshop manual, as well as the use of adequate technical facilities and the necessary personal pro-
tective equipment and tools needed to carry out diagnostic procedures, tear downs and rebuild procedures in
a safe and competent manner.

The information enclosed in this publication are provided "as is." There is no warranty either expressed or
implied, provided by Lotus cars regarding any of the information provided within these service notes, including
the implied warranties of merchantability and fitness for a particular purpose.

Lotus policy is one of continuous product improvement, and the right is reserved to alter specifications at
anytime without notice. Whilst every care has been taken to ensure correctness of information, it is impossible
to guarantee complete freedom from errors or omissions, or to accept liability arising from such errors or omis-
sions, but nothing herein contained shall affect your statutory rights.

How to use this manual

To rationalise the information contained within the service notes, the removal, refitment and/or replacement
information contained within each section has been divided into specific assembly areas or ‘function groups of
the vehicle.
Example:

Description area of the vehicle Service notes section

Front suspension CI
Rear suspension DH
Fuel system LJ

Each section is then divided into further sub-sections displaying information on specific components relevant to
that sub assembly i.e., CI.7 – spring/damper assembly.

When applicable ‘General Description’ information is displayed at the beginning of each section listing any rel-
evant features or functions of the complete assembly or sub assembly components.

Step by step component removal information is first displayed, with refitment information being described as
‘Reversal of removal’ unless additional procedures are necessary.

Specific torque tightening figures shown in Nm are displayed next to any relevant fixings noted.

Where applicable fixings are described by size and description i.e., M10 x 85 bolt or M10 nyloc nut.

Many removal/refitment procedures for individual specific components within an assembly may incur repeat
operations that have already been described within another sub-section of the service notes.

Therefore when this occurs, to avoid duplication of information and to limit the size of the service notes; a pro-
cedural step may contain the phrase 'See section XX.X'.

Referring to that section will display additional relevant strip down information applicable to the repair being
carried out.

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 Lotus Service Notes Introduction Section AA

VEHICLE IDENTIFICATION NUMBER & ENGINE NUMBER

SCCTC12219HN1000

ohs 228 ohs119a ohs104

The Vehicle Identification Number (V.I.N.) is viewable from the outside of the vehicle, located on a plate po-
sitioned between the left hand front edge of the dashboard and inside of the windscreen. It is also displayed
on a printed on a label stuck to the inside of the chassis sideframe alongside the driver’s seat. This label also
displays the Lotus paint code for the vehicle which can be identified as a 3 or 4 digit code prefixed with either
the letter ‘B’ of ‘C’. It is also stamped on the chassis in the right hand front wheelarch area, and can be viewed
with the front wheels turned to a right full lock.



5
 :2

1ZR/2ZR ENGINE NUMBER ohs176 1ZZ/2ZZ ENGINE NUMBER ohs133

1ZZ and 2ZZ engine numbers are marked on a vertical patch at the right hand side of the rear face of the cyl-
inder block, adjacent to the clutch housing.

On the 1ZR or 2ZR engine, the number is stamped on the left hand front of the cylinder block, alongside the
alternator, and is prefaced by ‘1ZR’ or '2ZR'.

Both V.I.N. and engine numbers should always be quoted with any vehicle enquiries, as Factory records are
filed against V.I.N., and specification change points are identified by V.I.N. or engine number. The vehicle
licence plate should be disregarded in this context as it may not accurately reflect vehicle age, and may also
be changed during the car’s life.

The V.I.N. comprises 17 characters, coded in accordance with European Economic Community (EEC) and
National Highway Traffic Safety Association (NHTSA) directives. For change point identification in Service
Notes, Service Bulletins and Service Parts Lists, typically, only characters 10 (model year), and 14 to 17 (serial
number) will be quoted.

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 Lotus Service Notes Introduction Section AA

2004 M.Y. - 2010 M.Y. serial no. 0359

Assembly
Plant Model
Vehicle Type H = Hethel 2 = 2-Eleven
Manufacturer 111 = Elise/Exige Check B = Shah 3 = Elise
Identifier Code 123 = 2-Eleven Digit Alam 8 = Exige

S C C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Engine Type Restraint Model Year Chassis/Body Serial

A = 2ZZ s/c 260 c/c A = Active belts 4 = 2004 A = LHD Fed. Number
C = 2ZZ 190 no evap C = Dual S.I.R. 5 = 2005 C = RHD
L = Motorsport + active belts 6 = 2006 D = LHD
N = 2ZZ s/c 255 7 = 2007 F = U.K. SVA RHD
P = 2ZZ 190 evap 8 = 2008 G = U.K. SVA LHD
V = 2ZZ s/c 220 c/c 9 = 2009 H = M/sport LHD* * Track only. Not
W = 2ZZ s/c 240 c/c A = 2010 J = M/sport RHD* approved for road use
Y = 1ZZ 140 L = LHD Fed. a.c.
Z = 2ZZ s/c 220 M = LHD Can. a.c.
N = RHD a.c.
P = LHD a.c.

2010 M.Y. serial no. 0360 onwards

Model Year Market Spec.
A = 2010 A = LHD USA G = LHD SVA
Restraint B = 2011 B = LHD Canada H = LHD Track
Model A = 3pt no SIR C = 2012 C = RHD Other J = RHD Track
HC = Elise C = Dual SIR D = 2013 D = LHD Other L = South Korea
Manufacturer HH = Exige L = 4pt no SIR E = 2014 E = Gulf States
Code NB = 2-Eleven S = 5pt no SIR F = 2015 F = RHD SVA

S C C L H
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Brand Engine Check Plant Build Type Serial Number

L = Lotus A = 2ZZ s/c 260 c/c Digit H = Hethel 1 = Std.
B = 2ZZ s/c 260 c/c 2 = Proto.
no evap
C = 2ZZ 190 no evap
L = Motorsport
P = 2ZZ 190 evap
R = 2ZR s/c 220 c/c
V = 2ZZ s/c 220 c/c
W = 2ZZ s/c 240 c/c
X = 1ZR 135
Y = 1ZZ 140
Z = 2ZZ s/c 220
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 Lotus Service Notes Introduction Section AA

MODEL HISTORY MILESTONES (does not include all special editions)

Elise 111R Introduction: January 2004

VIN character 4 = P; Character 13 = 3; Serial number from 0970
Note that the serial number sequence is shared with other Elise variants.
Changes from previous model include: Toyota powertrain with 1.8 litre VVTL-i engine and 6-speed trans-
mission. Twin exhaust tailpipes exiting through centre of diffuser. Larger fuel tank with new pump. Revised
chassis rail rear ends, new rear subframe, revised seat belt mounting frame backstays. Revised rear suspen-
sion wishbones, springs and dampers. ABS brake control with vacuum servo. Revised front bonnet grilles
and access covers.

2004 Exige Introduction: March 2004

VIN character 4 = P; Character 13 = 8; Serial number from 1092
Note that the serial number sequence is shared with other Elise variants.
Differences compared with Elise 111R include: Restyled front and rear clamshells with roof scoop, new
tailgate panel and strut mounted rear aerofoil. Front body splitter panel. Re-styled road wheels, wider on the
front, and Yokohama A048 tyres.

2005 M.Y. Elise for North America: May 2004

VIN character 10 = 5; Character 12 = L; Serial number from 0001
Note that the serial number sequence is shared with other Elise variants when '05 M.Y. is adopted for
those models later in the year.
Differences compared with Elise 111R include: Driver and passenger airbags, pyrotechnic seat belt pre-
tensioners; Re-styled fascia and dashboard structure; Front speakers moved onto top surface of fascia, stow-
age pockets incorporated into dashboard end panels, fixed windscreen demist vents. Engine start button in
driver's side switch panel. Revised springs and dampers, Yokohama AD07 tyres. Side marker lamps on front
and rear wheelarch lips. Revised fuel system with fuel filler flap.

Lotus Sport Exige 240R: March 2005

Limited edition of 50 units produced as post registration official factory conversions of '05 Exige by the
Lotus Sport workshops at Hethel, for U.K. and certain overseas territories. The car is not identifiable from the
VIN coding.
Differences compared to standard Exige include: 243 bhp engine upgrade using Eaton M62 supercharger
with integral by-pass valve, air/air chargecooler and 5th fuel injector. Re-programmed ECU. Accusump.
Stiffened springs & Ohlins adjustable dampers. Adjustable front anti-roll bar. Chassis rear brace kit. Forged
5-spoke widened roadwheels & Yokohama A048 tyres. Motorsport brake pads, braided hoses, yellow callipers,
Castrol SRF brake fluid. Sport Yellow body colour with black wheels, or Sport Black body with silver wheels.
Black interior with yellow inserts. 4-point harnesses, T45 roof hoop and backstays.

2006 M.Y. Introduction: September 2005

VIN character 10 = 6; Serial number restarts at 0001, common to all variants.
Introduction of USA Exige and Canadian Elise.
5-speed Elise remains unchanged.
Differences between 6-speed '06 Elise and '05 include; Electronic throttle control (using no mechanical
cable). Optional Lotus Traction Control (LTC) or Limited Slip Differential (LSD) with LTC. Standard fit Yokohama
AD07 tyres on non-USA cars. Optional forged wheels with new 6.0 in front size. LED rear lamp clusters incor-
porating reflectors (formerly separate), and commonised USA type CHMSL. ProBax seat foams. New body
colours. USA & Canadian Elise; revised fuel tank and evap. loss system. Canadian Elise uses daytime running
lights and clutch down start allow switch. USA Exige similar to non-USA, but with USA airbag interior.

Sports Racer: October 2005

Special paint versions of '06 M.Y. 111R in either Ardent Red with triple Monaco White stripes, or Nightfall
Blue with twin Monaco White stripes. Combined total of 199 units with unique build plate on sill. Forged wheels
(6J on front), AD07 tyres, sport suspension, twin front oil coolers, LTC. Black leather interior with red or blue
stitching, and red or blue 'Elise' embroidered into head restraints. Sports Racer decals.

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 Lotus Service Notes Introduction Section AA

Exige Cup 190 & 240: January 2006

Limited number of competition oriented naturally aspirated (190) or supercharged (240) models produced
as post registration official factory conversions of '06 Exige by the Lotus Sport workshops at Hethel for U.K.
and certain overseas territories. Not identifiable from VIN coding.
Differences compared to 240R (see above) include: Electronic throttle, high flow port injectors (no 5th).
Cup 240 fitted with torque sensing LSD with LTC. Cup 190 uses friction plate LSD. Standard Exige wheels in
'Hi-power' silver. Race cars fitted with FIA 6-point roll cage, remote kill switch, extinguisher system. Standard
body colours.

Exige S: February 2006

VIN character 4 = V
Factory built type approved supercharged Exige. Not USA.
Differences to standard Exige include: 221 PS supercharged engine similar to 240R but using electronic
throttle, smooth flow inlet adaptor, standard injectors without 5th injector, modified downpipe, optimised muffler
with single oval tailpipe. Enlarged roof duct inlet for chargecooler. Body colour splitter, scoops and aerofoil.
'Exige S' decal on rear transom, 'S' on front quarter panels.

USA Lotus Sport Elise: March 2006

Limited edition of 50. Saffron Yellow with twin Storm Titanium stripes. Saffron Yellow centre console. Yel-
low highlighted sports seats, 'carbon' door trim inserts. Harness bar, T45 seat belt mounting frame. Motorsport
mats, stalks, winders and parking brake sleeve. Traction control, supersport suspension, black forged wheels,
Yokohama A048s, braided brake hoses, silicone fluid, motorsport clutch. Lotus Sport decals and Union flags.
Lotus Sport chassis plate.

2007 M.Y. & Elise S Introduction: June 2006

VIN character 10 = 7; Serial number restarts at 0001, common to all variants.
VIN character 4 identifies engine type. Elise S = Y
Differences between '07 Elise/Exige and '06 include: Elise 111R renamed Elise R; New sealed headlamp
units; raised LOTUS lettering on rear transom; additional screen pillar seal; Alpine audio; improved HVAC duct-
ing. New model Elise S uses 1ZZ-FE engine producing 100 kW, with variable inlet timing but fixed valve lift,
plastic inlet manifold, revised intake snorkel, revised exhaust manifold and downpipe, smaller tailpipes within
standard trims. Elise S also uses new C56 5-speed transmission and 6-spoke roadwheels sharing styling of
standard '01 model wheels.

USA Exige S: October 2006

The specification of the USA Exige S is that of the standard USA Exige and option packs, apart from the
engine, which is as non-USA Exige S with the following exceptions: High flow port injectors, specific engine
programming, 223 PS, 223 Nm. Carry-over features from the non-USA Exige S include exhaust downpipe and
optimised muffler with single oval tailpipe, roof air intake funnel mouth.

Exige S British GT Special Edition: November 2006

Celebrating Lotus Sport Cadena’s 2006 British GT3 Team Championship victory.
Differences to standard Exige S include: Torsen LSD & Lotus Traction Control. Chassis rear brace kit.
T45 roof hoop & stays. Braided brake hoses. Level 1 sports exhaust. Forged 7-bifurcated spoke silver wheels.
Lotus Sport black metallic body colour with Sport yellow & Arctic silver quad stripes, supplier decals on sills,
Lotus Sport visor strip, Cadena decals on front wings, GT3 decal on rear clam, GT3 winners decal with unique
build number on rear quarter panel, Lotus Sport build plate with build number. 4-point harnesses, black/yellow
door trims and unique black/yellow trimmed seats. Optional a.c. Optional GT pack available as post registration
official factory conversion by Lotus Sport workshops at Hethel for U.K. and certain overseas territories, includes:
High flow injectors, different ECU & unique calibration for 243 bhp, Accusump, 2-way adjustable Ohlins dampers
with uprated springs, 308mm front discs & 4-piston A.P. callipers, Pagid pads, Castrol SRF brake fluid.

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 Lotus Service Notes Introduction Section AA

USA Low Speed Damage Mitigation: January 2007

From ‘07 USA VIN serial no. 1579.
To meet USA safety legislation, modifications made to Elise/Exige: Front; armatures and foam inserts
added between crash structure and clamshell. Rear; bumper panel housing foam pads either side of licence
plate, narrower rear grilles, reinforced boot floor and diffuser support panel, stiffened diffuser. Some elements
commonised for all markets.

Lotus Sport Exige Cup 255: January 2007

Produced as post registration official factory conversions of '07 Exige S by the Lotus Sport workshops at
Hethel for certain territories, excluding U.K. and USA. Not identifiable from VIN coding.
Based on Exige Cup 240 (see above) with following differences: Power increase to 255 PS by; unique
ECU calibration, enlarged chargecooler, extended roof duct, larger air cleaner and intake spout, uprated fuel
pump. A.P. Racing 4 piston alloy front callipers, 308mm front discs.

2-Eleven Introduction: May 2007

VIN character 6/7/8 = 123; Character 13 = 2
Extreme, minimalist, track focussed Elise variant based on Exige Cup 255 powertrain componentry, but
using new chargecooler arrangement. Produced in small numbers for U.K. and certain overseas territories. In
U.K. only, SVA road going version available. All other territories only for track use, in LHD or RHD.
New body with no doors or roof. Aeroscreen. Rear aerofoil in two versions. FIA compliant roll over bar.
Chassis rear brace, unique front top wishbones and steering arms, optional Ohlins suspension. Accusump,
twin front oil coolers. Standard LTC, optional variable LTC & Launch Control. Uprated clutch. Odyssey battery.
Limited warranty for SVA cars. Extensive options list.

USA Elise Limited Edition 'Type 72D'

Limited edition of 50 cars to commemorate the 35th anniversary of Lotus' F1 1972 World Championship
victory with the type 72D.
Phantom black body colour with hand painted gold pinstriping. Rear body spoiler, black diffuser. Gold
laurel leaf decal on front quarters, gold 'Elise' and 'Type 72D' decals, gold raised LOTUS lettering, gold/black
nosebadge, gold fuel filler cap. Gold Exige 8 split-spoke wheels with Yokohama A048 tyres and sports suspen-
sion. Black & gold seats and interior trim details with Limited Edition plaque. Scale model crash helmet.

Club Racer: September 2007

Limited edition of 25 for U.K. Unlimited for Europe.
For U.K., spec. based on '07 Exige S with Sport, Touring & Super Touring packs and a.c.. Sports exhaust
supplied for dealer fitment.
For Europe, spec. based on '08 Exige S (see below) with Sport and Performance packs. Forged
wheels.
All cars: Hethel track decal on rear transom, Le Mans blue body with Phantom black triple stripe. Black
leather and carbon effect trim with colour coded stitching.

Introduction of 2008 Model Year Elise/Exige: October 2007

VIN character 10 = 8. VIN serial number restarts at 0001. Exige N.A. built only to special order.
All cars now with dual airbags and start button in matt charcoal finish fascia. PFK 457 security system
with Lotus design transmitter key. Tyre pressure monitoring for USA only. High rpm sequential tell tales. CAN
bus diagnostics using laptop Lotus Techcentre. New paint colours. Performance Pack option (VIN character
4 = W) with 240 hp calibration, high flow injectors, big roof scoop, uprated clutch, 4-piston front brake callipers
and enlarged front discs, variable traction and launch control (excludes warranty).

Elise S Hethel 40th Limited Edition: October 2007

Commemorating 40 years of production at Hethel. All LHD.
'08 M.Y. Elise S in Burnt Orange with hardtop. Orange body grilles and centre console. Black diffuser
and wheels. Black leather seats and door trim with orange stitching. Build plaque. Country decals below side
repeater lamps. 7 Union Flag, 6 Swiss, 2 Belgium, 4 French, 10 German, 6 Italian.

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 Lotus Service Notes Introduction Section AA

Elise 'California' Limited Edition: October 2007

USA only. 25 off Ardent Red with cream/red leather and champagne trim; 25 off Saffron Yellow with black
leather and champagne trim.
Based on USA Elise with touring pack. Rear body spoiler. Silver front intake grilles, other grilles in body
colour. 16-spoke cast wheels in Hi-power silver, AD07 tyres. Lotus roundel and California decals on front
wings. Sports seats in cream & red or black leather. Other trim in cream & red or black leather. Hardtop lining
in Beige cloth. RHD footwell divider.

Exige Sprint: November 2007

Limited edition of 40 cars for U.K. market, one for each year from 1967 to 2006. +20 E.U. +2 Japan.
'08 M.Y. Exige S with Sport, Touring and Performance Pack, a.c., black forged wheels, 2-tone paint in
Aspen White and either Persian Blue or Saffron Yellow, with gold decal strip and 'Exige Sprint' logo. Union flag
on rear body, laurel decal on LHR quarter, colour coded leather seats and trim, embroidered footwell carpet
mats. Build plaque on chassis sill.

Introduction of Elise SC: February 2008 (final '07 M.Y. serial no. 3579)
Supercharged Elise without chargecooler.
VIN character 4 = Z
Based on Elise R, but using new Eaton M45 supercharger rotor pack integrated into inlet manifold, high
flow fuel injectors and unique calibration to produce 220 PS. Rear body spoiler, Lotus styled 12-spoke road
wheels in 6.0 and 8.0 front/rear widths, standard AD07 tyres. Wheelarch lips on non-USA cars. 'Elise Super-
charged' decals on rear transom and front wings.

Lotus Sport Exige Cup 260: February 2008

Fully Type Approved version of Exige Cup 255 (see above).
VIN character 4 = A
Based on Exige S with: Big roof scoop, high output fuel pump, unique calibration to produce 260 PS.
Accusump, lightweight flywheel, uprated clutch, Torsen LSD, Variable Traction and Launch control (excludes
warranty). 4-piston front brake callipers and enlarged front discs, braided hoses, Bilstein or Ohlins adjustable
spring/dampers, stiff adjustable ARB in hard mounts, hi-power silver 16-spoke cast wheels, A048 tyres. FIA
compliant battery isolator and plumbed-in fire extinguisher. T45 seat belt anchorage frame. FIA compliant
cage and 4-point harnesses supplied separately. NO airbags and none pre-tensioner 3-point belts. No CDL.
Black Alcantara/carbon effect seats and door trim. Build plaque on dash, 'Lotus Sport' decal on front quarter
panels, 'Cup 260' decal on rear transom, black diffuser. Restricted warranty.

USA Elise SC '60th Anniversary': May 2008

Limited edition of 60 USA cars to commemorate 60th anniversary of Lotus Cars.
Based on Elise SC with hard and soft tops, Touring and Sport Packs, supersport suspension, forged
wheels, A048 tyres, T45 seat belt frame & harness bar. Body and double stripe paint in BRG/Saffron, Saffron/
Black, Black/Arctic, Storm Titanium/Canyon Red. Complimentary trim inserts and 60th Anniversary embroidery.
Anniversary decal on rear transom.

Clark Type 25 Elise SC: June 2008

Limited edition of 25 U.K./25 E.U./25 USA cars to commemorate 40th anniversary of Jim Clark's death.
Donation to the Jim Clark memorial fund.
Based on Elise SC with hard top and Sport Pack. BRG (B04) with Saffron single centre stripe, Lotus Sport
wheels with black spokes and silver rims, A048 tyres. Black & red leather themed interior, with sports seats,
wood gearknob and build plaque. Type 25 decal on rear transom, Jim Clark signature on LH buttress and inner
door panels, race roundels on doors with Type 25 decals. USA cars used 7-splitspoke black forged wheels,
alloy gear knob, black diffuser.

2009 M.Y. Introduction: September 2008 (final '08 cars: Elise 2308; Exige 2304; 2-Eleven 2292)
VIN character 10 = 9. VIN serial number restarts at 0001.
No changes apart from Cup 260.

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 Lotus Service Notes Introduction Section AA

2009 M.Y. Lotus Sport Exige Cup 260: October 2008

Lightweight body panels using carbon fibre, rear window deleted from rear bulkhead. Lightweight com-
ponents incl. battery, c/c U-bends, billet flywheel, new forged 12-spoke roadwheels in 7 & 8 inch widths, rear
subframe with DeltaProtekt coating, deletion of footwell pads, interior mirror, sunvisors, tailgate strut. HANS
approved seats. Body coloured SBAF 'A' frame. Chassis drilled for front cage. New body graphics.

2010 M.Y. Introduction: May 2009 (final '09 cars: Elise 375; Exige; 202; 2-Eleven 57; USA Elise 140 USA
Exige 46)
VIN character 10 = A. VIN serial number restarts at 0001.
Elise range unchanged. Exige S (on USA & Gulf only from 0360): Front clamshell with restyled lower sec-
tion including larger air intake ducts with a horizontal vane in each oil cooler duct. New full width body colour
front splitter. Wider, body mounted rear aerofoil, supported by end plates. All models: reduced emissions and
improved economy figures.

2010 M.Y. Lotus Sport Exige Cup 260: August 2009

Adoption of Exige S front clam and rear aerofoil (see above) using some carbon elements. Strengthened
engine bay undertray with new fixings to provide 'shear panel' stiffening of subframe suspension mounts. Ohlins
2-way adjustable dampers. Lightened Lotus Sport 5-spoke wheels. Carbon centre console.

Exige S Type 72: December 2009

Celebrates Type 72 F1 twenty GP victories. Limited edition of 20 for U.K., 20 for Europe, plus selected
RoW territories. Phantom Black with gold pin-striping, gold Exige S on rear, Type 72 on passenger 'B' panel.
Sport and Touring Packs. Machined forged 5-spoke wheels in black and gold. Black microfibre trim with gold
stitching. Build plaque with GP win.

Exige Scura/Stealth: January 2010

Limited edition of 35 cars for Europe and some RoW territories. Badged as 'Stealth' for Japan. Based
on Exige S with Cup 260 features including powertrain, suspension and body. Soft feel matt black paint finish
with gloss Phantom Black triple stripes. Forged 10-splitspoke wheels in matt black. Laquered carbon fibre
seat shells and centre tunnel. Anthracite gear knob and parking brake sleeve.

2011 M.Y. Introduction: March 2010 (final ‘10 cars: Elise 567; Exige 333; 2-Eleven 35; USA Elise 35;
Exige 60)
VIN character 10 = B. VIN serial number restarts at 0001.
Exige range unchanged. Changes to Elise range include: Revised front body with enlarged oil cooler intake
ducts and chin spoilers, restyled radiator outlet ducts, one-piece lift out access cover, aluminium mesh grilles.
Revised rear body with restyled bumper incorporating licence plate plinth, new engine/boot lid, aluminium mesh
grilles, separate rear transom panel without faux end grilles, new diffuser. New headlamp units incorporating
LED turn lamps and LED daytime running lamps. New 12-spoke cast roadwheels, or new 5-'Y'spoke forged
wheels. Elise S model replaced by base Elise with 1.6 ltr. IZR FAE engine, featuring inlet and exhaust cam
VVT-i, and VALVEMATIC inlet valve lift control, Lotus T6 controller; new 6-speed type EC60 transmission;
revised rear subframe; optional cruise control.

Elise SC and Exige S RGB Special Editions: September 2010

Limited edition of cars to celebrate the career of Roger Becker (RGB) the former Director of Vehicle En-
gineering who retired in January 2010 following 44 years of service. Based on the Elise SC and the Exige S
with Sports and Touring packs, rear subframe shear panel (Exige S only), Lotus ultra lightweight forged alloy
wheels and air conditioning as standard. Produced in four colours, Aspen White, Starlight Black, Solar Yellow
& Carbon Grey. RGB special editions are identified by a numbered interior plaque, Roger Becker’s signature
decals on the side of the bodywork and special monochrome Lotus nose badge.

Introduction of Lotus Dynamic Performance Management (Lotus DPM)

Introduced at VIN BH_10391 in September 2011 for Elise with1ZR powertrain only.
Kelsey Hayes ABS system replaced with Bosch ABS modulator incorporating electronic stability control
referred as Lotus Dynamic Performance Management and HBA (Hydraulic Brake Assist). Revisions to tell tale
lamps include addition of side light tell-tale, cruise control tell-tale (previously located on centre console) Lotus
DPM tell-tales and revised functionality of coolant temperature tell-tale and LCD display.

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 Lotus Service Notes Introduction Section AA

Elise CR (Club Racer): February 2011

Based on 1ZR powertrain for Europe and some ROW territories. Introduced as the entry level variant to
the Elise range. Increased power to weight ratio over standard 1.6 Elise by deletion of certain standard factory
fitted components such as carpets, radio and speakers, passenger footrest, central locking, mudflaps, NVH
material and soft top roof (shower cover supplied). Lightweight battery fitment with isolator switch available to
replace standard battery. Additional customer optional delete of airbag and pyrotechnic seat belt system as
well as Dealer option fit of lighter weight forged wheels and ‘power pack’ consisting of TRD airbox, high flow
filter and level 1 sports exhaust. A ‘Sport’ mode button is fitted as standard and located in the centre console
opposite Lotus DPM switch. Sports suspension fitted as standard with adjustable yellow Anti-Roll bar. Avail-
able in Saffron Yellow B106, Ardent Red C94, Sky Blue C124, Aspen White C113, Carbon Grey B137 & Matt
Black B141. The CR is fitted with a ‘Black Style Pack’ as standard, which includes a matt black finish to the roll
hoop cover, the rear transom panel and door mirror covers. Elise CR logos R/H rear clamshell & LH/RH front
clamshell above the side repeaters, top of roll hoop cover & door interior. A rear ‘LOTUS’ decal replaces the
rear 3D ‘LOTUS’ badge but still uses the standard Lotus logo nose badge. Body coloured seats, with SuedeTex
pads, body coloured painted centre console with the Elise CR decal. Matt black radio blanking panel with CR
decal. SuedeTex trim to door inserts, handbrake/gearlever gaiter and elements of the steering wheel (including
steering wheel centre if airbag delete option selected). See Technical Service Bulletin 2011/09 for full details

Elise S: June 2012

Introduced at VIN CH_10205 VIN character 7 engine type = R (2ZRFE engine, supercharged with I.C.
- 162.5Kw). ENGINE: Fitted with type 2ZR-FE 4 cylinder engine 1.8 litre features dual Variable Valve Timing -
intelligent (VVT-i) The engine is uprated by the fitment of a Magnuson R900 supercharger (utilising Eaton TVS
Technology TM) with an integral air to water charge cooler and inlet manifold. COOLING: The charge cooler
system utilises its own dedicated coolant circuit with a coolant reservoir mounted on the left hand side of the
engines cylinder head. Charge cooler coolant is circulated to a single front mounted coolant/air cooler radiator
positioned ahead of the left hand front road wheel. Additional engine oil cooling is provided with the fitment of a
single front mounted oil/air cooler radiator positioned ahead of the right hand front road wheel. TRANSMISSION:
The Elise S utilises the same Toyota sourced EC60 transmission assembly as used on the Elise 1.6, but is fitted
with a higher rated clutch centre plate to accommodate the increased torque. SUSPENSION: is unchanged from
the Elise 1.6 litre, with uprated springs and dampers available with the selection of the ‘Sports’ pack option. Also
included within the ‘Sports’ pack option are the latest forged, 7 ‘Y’ spoke 6.0J x 16 front and 8.0J x 17 rear wheels
available in either silver or black specifically developed for the introduction of the Elise S. ELECTRICAL: An
additional USB 5 volt DC charging port (if fitted) is located in the passenger storage pocket. FUEL: An uprated 4
bar fuel pump is fitted to ensure that an adequate delivery of fuel to the injectors is available under high engine
torque/demand scenarios. See Technical Service Bulletin 2012/07 for full details.

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 Lotus Service Notes Introduction Section AA

JACKING & LIFTING POINTS AA.1

Care must be taken when using a lifting jack or hoist to position the device only in one of the the areas shown
in the illustration, with a suitable rubber or timber pad protecting the chassis from surface damage. If a 4-point
lift is to be used, the engine bay undertray/diffuser panel (if fitted) must first be removed. When using a 4-point
lift, it is strongly recommended that for optimum stability and safety, positions B and D are used.

A; Identified by a blue sticker. Beneath crossmember ahead of fuel tank bay. To be used one side at a time
for wheel changing - lifts both wheels on one side. Do not use with a four point garage lift.
B; Beneath the front end of the right or left hand main chassis rail, behind the front wheelarch. Garage use
with 4-point lift in conjunction with (C).
C; The engine undertray/diffuser panel must first be removed. Beneath the outboard end of the chassis
crossmember ahead of the rear wheelarches. Take care to position the jack between the fixing screws
for the fuel tank bay perforated undershield. Garage use with 4-point lift in conjuction with (B).
D; The engine undertray/diffuser panel must first be removed. Beneath the rear subframe, close to the lower
wishbone rearmost mountings.
Jacking at any other point may damage the chassis or body structure and/or jeopardise safety.

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 Lotus Service Notes Introduction Section AA

ENGINE BAY UNDERTRAY/DIFFUSER AA.2

For certain service operations, it may by necessary to remove the engine bay undertray and/or diffuser panel.
The panels contribute to the aerodynamic performance of the car, and also help to keep the engine bay clean.
Do not run the car without the panels fitted.

Note: To ensure its security, any speed fixings used to retain the undertray screws must be renewed before
refitting the undertray/ diffuser assembly onto the vehicle.

All M5 screws tightened to a torque of 5 Nm

All M6 screws tightened to a torque of 8 Nm
All M8 screws tightened to a torque of 20 Nm.

Typical model shown - others similar

3 screws to licence 1 screw each side

plate plinth to grille panel

b275b

Diffuser panel
3 screws
each side
Single screw each to tank bay
side to clamshell panel
Undertray
front edge
M8 button head slots into
(2) to subframe 5 screws M8 button head chassis
undertray (2) to lower
to diffuser link brackets

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 Lotus Service Notes Introduction Section AA

ENGINE BAY UNDERTRAY/DIFFUSER AA.3

For certain service operations, it may by necessary to remove the front undershield. The panel contributes to
the aerodynamic performance of the car, aids the rigidity of the front clamshell panel and retains the auxiliary
radiator brackets in situ. Do not run the car without the panels fitted.

The undershield panel is fixed to the vehicle using M5 and M6 sized fixing screws, which are either bolted
directly into the vehicles chassis and crash structure or retained by the use of single use speed fixings also
referred to as ‘spire nuts’.

Note: To ensure its security, any speed fixings used to retain the undershield screws must be renewed before
refitting the assembly back onto the vehicle.

All M5 screws tightened to a torque of 5 Nm

All M6 screws tightened to a torque of 8 Nm

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 Lotus Service Notes Introduction Section AA

vehicle Recovery AA.4

Recovery Anchorage Mounting Point

A recovery anchorage mounting point is fitted behind the centre
front radiator air intake grille. The mounting point is provided to
aid vehicle recovery, such as winching onto a flatbed car trans-
porter, but only when the car is able to roll freely.

Recovery Eye
A recovery eye is provided with the vehicle tool kit, and stowed
in the rear luggage compartment. When required, fit the eye to
its anchorage point having first removed the protective bung (if
fitted), and screw fully into the tapped boss.

Only in an emergency should the car be towed using this anchor-

age mounting, and then only for the shortest distance necessary,
during which time the following precautions must be taken: ohs216

WARNING: Use only towing equipment designed specifically for this purpose, or damage to the car may
be caused, or you could be killed or seriously injured. Ensure that the key is used to unlock the steer-
ing column, and is then left in the lock. Never withdraw the key until the car is stationary. The steering
column will lock when the key is withdrawn.

NOTICE: Before being towed:

• Release the parking brake and ensure that the transmission is in neutral.
• Comply with all local legislation applicable to cars being towed.
• Do not use the recovery eye to secure the car on a transporter. (see ‘Car Tie- Down’ below).

Car Tie-Down
When moving a car by transporter or trailer, the car should be secured only by chocking and strapping around
the road wheels.

NOTICE: Attaching restraints around suspension linkages or chassis or body components may cause dam-
age.

Vehicle Recovery
The recommended method of recovery for any model is the
A
use of a flat bed transporter as shown in illustration B.

Never use the recovery eye to tow the vehicle. To prevent

causing serious damage to the transmission; always tow the
vehicle with the free wheels (non driving wheels) rotating on
the ground, see illustration A.
B

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