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Lotus Elise / Lotus Exige. Instruction - part 3

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Lotus Service Notes

Section TDP

GENERAL

Type designation - All except Elise S

2ZZ-GE

- Elise S

1ZZ-FE

Conﬁguration & no. of cylinders in-line 4 -

Capacity 1796 cm

1794 cm³

Bore 82.00 mm 79.00 mm

Stroke 85.00 mm 91.50 mm

Camshafts Chain driven DOHC -

Valves 4VPC in pentroof -

chambers

Valve control - inlet Variable timing & lift Variable timing

- exhaust Variable lift -

Valve timing - inlet - low & medium speed - open 33° BTDC to all speeds 48° BTDC

to 10° ATDC to 5° BTDC

- close 15° ATDC to all speeds 12° ATDC

58° ATDC to 55° ATDC

- high speed - open 58° BTDC to

15° BTDC

- close 54° ABDC to

97° ABDC

- exhaust - low & medium speed - open 14° BBDC all speeds 42° BBDC

- close 34° ATDC all speeds 2° ATDC

- high speed - open 36° BBDC

- close 60° ATDC

Compression ratio 11.5:1 10.0:1

Compression pressure (250 rpm) - new 1400 kPa (203 psi) 1500 kPa (218 psi)

- service limit 1000 kPa (145 psi) -

Firing order 1,3,4,2 -

Spark plugs NGK IFR6A11 NGK BKR5EYA-11

Spark plug gap 1.1 mm 1.0 ± 0.05 mm

Maximum continuous engine speed 8000 rpm 6,800 rpm

Maximum transient engine speed 8500 rpm 7,000 rpm

Idle speed 850 rpm -

Ignition system Direct ignition using -

individual H.T. coils

for each cylinder

Fuel system Fully sequential -

indirect fuel injection,

Lotus T4 controller

Fuel requirement (minimum) Unleaded 95 RON -

Peak power (1999/99/EC) 141 kW (192 PS) 100 kW (136 PS)

@ 7,800 rpm @ 6,200 rpm

Peak torque (1999/99/EC) 181 Nm 172 Nm

@ 6,800 rpm @ 4,200 rpm

Exhaust emissions - CO 0.42 g/km 0.23 g/km

- HC 0.078 g/km 0.050 g/km

- NOx 0.0121 g/km 0.0217 g/km

- HC + NOx 0.0792 g/km 0.0717 g/km

- CO

208 g/km 196 g/km

CYLINDER BLOCK

Material Aluminium alloy, Aluminium alloy,

MMC cylinder bores cast iron liners

Deck face ﬂatness tolerance 0.05 mm -

Cylinder bore diameter 82.000 - 82.013 mm 79.000 - 79.013 mm

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Lotus Service Notes

Section TDP

CYLINDER HEAD

2ZZ-GE 1ZZ-FE

Material Aluminium alloy -

Head face ﬂatness tolerance 0.05 mm -

Reface limit No machining -

VALVES & SPRINGS

Valve seat angle in head 45° -

Valve face angle 44.5° -

Cold valve clearance (between cam & follower) - inlet 0.10 - 0.16 mm 0.15 - 0.25 mm

- exhaust 0.24 - 0.30 mm 0.25 - 0.35 mm

Valve guide standout 15.3 - 15.7 mm 8.7 - 9.1 mm

Valve spring free length - inlet 46.4 mm 45.9 mm

- exhaust 46.5 mm 45.9 mm

CAMSHAFTS

End ﬂoat - new 0.04 - 0.14 mm 0.04 - 0.10 mm

- service limit 0.15 mm 0.11 mm

PISTONS

Diameter - @ 90° to pin, 12 mm from bottom edge 81.975 - 81.993 mm

- @ 90° to pin, 25 mm from top edge 78.925 - 78.935 mm

Ring gap, 110 mm from block top face - std. - no.1 0.25 - 0.35 mm -

- no.2 0.35 - 0.50 mm -

- oil rail 0.15 - 0.40 mm -

- max. - no.1 1.1 mm -

- no.2 1.2 mm -

- oil rail 1.1 mm -

Ring groove clearance 0.030 - 0.070 mm -

CONNECTING ROD

Small end bush inside diameter 20.011 - 20.023 mm 20.012 - 20.021 mm

Big end side clearance 0.16 - 0.34 mm -

CRANKSHAFT

Crankshaft endﬂoat - new 0.04 - 0.24 mm -

- service limit 0.30 mm -

Main journal diameter 47.988 - 48.000 mm -

Crankpin diameter 44.992 - 45.000 mm 43.992 - 44.000 mm

Max. taper & out of round, journals & crankpins 0.02 mm -

OIL PUMP

Oil pressure - idle, running temperature 39 kPa (6 psi) min. 29 kPa (4 psi) min.

- 3,000 rpm, running temperature 300 - 540 kPa -

(45 - 80 psi)

Outer rotor to housing clearance - new 0.13 - 0.18 mm -

- service limit 0.33 mm -

Inner rotor tip clearance - new 0.06 - 0.18 mm -

- service limit 0.33 mm -

Rotor end ﬂoat - new 0.03 - 0.08 mm -

- service limit 0.16 mm -

COOLANT THERMOSTAT

Valve opening temperature 80 - 84°C -

Valve lift at 90°C 10 mm -

Header tank pressure cap 108 kPa -

Cap opening pressure 93 - 123 kPa -

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Lotus Service Notes

Section TDP

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Lotus Service Notes

Section TDP

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