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Lotus Elise / Lotus Exige. Instruction - part 73

Page 14

Lotus Service Notes

Section MP

Engine Compartment

Fuses and relays associated with the

engine management system are contained

in two 4-position fuse holders located at the

front of the engine bay on the cabin bulkhead,

adjacent to the engine ECM. To access the

fuses, unclip rear edge of the cover.

Fuse no. Rating

Circuit

20A

Fuel pump

Immobiliser

Alternator sense

ECU battery feed

O2 heaters

7.5A

VSV's VVT, VVL, IAC

10A

Injectors, ignition coils

Re-circ. pump

Interior Fuses & Relays

The wash/wipe module, turn/hazard

ﬂasher relay, horn relay and a relay for inertia

switch activation of the central door locking,

are mounted on the scuttle beam above the

passenger footwell, with four fuses secured to

the harness in that area.

Fuse no. Rating

Circuit

20A

Interior fan

15A

Wiper motor

7.5A

Audio key-in

10A

A.C. compressor

A 60A Maxi fuse protecting the ABS circuit is located beneath the passenger side fascia top, adjacent to

the positive post.

A multi-function relay unit containing the engine control relay, fuel pump relay and starter relay is mounted

in the engine bay near the ECU. A similar relay unit is mounted in the front services compartment alongside

the fusebox, and operates the a.c. compressor and radiator fans.

Important Note: Although the two modules

are identical in appearance, their function is different and they must not be transposed. The a.c. relay module

A117M0038F has a brown label marked YWB100800; The engine relay module A111E6024F has a white label

marked YWB100970.

For the location of the vehicle alarm system components, see sub-section MP.1.

Fuse colours:

2A - Black

3A - Violet

4A - Pink

5A - Orange

7.5A - Brown 10A - Red

15A - Light Blue 20A - Yellow

25A - Clear

Relay Position

RHD:

Inboard top;

Wiper

Inboard bottom;

Flasher

Outboard top;

CDL trip

Outboard bottom;

Horn

LHD:

Inboard top;

Flasher

Inboard bottom;

Wiper

Outboard top;

Horn

Outboard bottom; CDL trip

ENGINE BAY FUSES

4 6

3 5

ohs136

Front Fusebox ‘C’

Viewed

from

beneath

m248a

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Lotus Service Notes

Section MP

Component Location

MP.6 - AUDIO EQUIPMENT

The Elise may be speciﬁed with various

audio equipment options. All cars are ﬁtted

with a main wiring harness which includes:

an ISO 16-way connector located behind the

standard ISO size audio aperture in the dash

panel; speaker wiring terminating behind

the cabin LH rear corner trim panel; and an

analogue di-pole aerial routed inside the front

body. On cars factory built with a digital audio

set, this aerial is supplemented by a digital di-

pole aerial routed in a similar manner.

Speakers

'Two speaker' cars are fitted with a

speaker in each cabin rear corner in a sound

deadening full width rear bulkhead trim panel.

An upgraded audio option uses the same

rear speakers, in conjunction with a pair of

front speakers, mounted one in each dash

end panel. USA cars have the front speakers

mounted in the fascia top panel.

CDL module Engine bay fuseboxes

Horn mounted

on crash structure ECU

mounting

plate

Fusebox

Inertia

switch

Radiator fan/a.c.

control module

Fuse

ABS block

fuse

Switch Horn relay

pl1703mt

controller CDL trip relay

Flasher unit

Wiper delay

Front speaker

Speaker

grille

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Lotus Service Notes

Section MP

Speaker speciﬁcations are as follows:

Rear: Blaupunkt GTX 542 2-way co-axial; 90W max; 30W RMS; 4 ohms impedance.

Front: Blaupunkt TSX 402 2-way co-axial; 105W max; 35W RMS; 4 ohms impedance.

To remove the rear bulkhead trim panel, remove the four screws securing the top edge of the panel to the

bulkhead plinth, and ease the panel from behind the seat belt mounting frame at each side.

MP.7 - BATTERY, BATTERY CABLES & EARTHING POINTS

Battery

WARNING: POISON/DANGER - CAUSES SEVERE BURNS - KEEP OUT OF REACH OF CHILDREN.

Contains sulphuric acid - avoid contact with skin, eyes or clothing. If in contact with skin or eyes; ﬂush

with copious amounts of water. Remove contaminated clothing. Seek immediate medical attention. If

ingested; seek immediate medical attention . Do not induce vomiting or give ﬂuids to drink.

Batteries produce explosive gases. Keep sparks, ﬂames and cigarettes away. Ventilate when charging

or using in enclosed space. Always shield eyes when working near batteries.

Battery Access

The 45 Ahr Yuasa type 063/3 battery is located at the left hand front of the rear luggage compartment.

No routine inspection or topping up of the electrolyte is required, but at intervals speciﬁed in the Maintenance

Schedule, the battery terminals should be checked for security and condition, and protected with petroleum

jelly.

To remove the battery, unhook the plastic cover, disconnect both battery cables (see below), and pull

off the breather pipe (if applicable). Release the single screw securing the clamp bracket at the rear base of

the battery, and manoeuvre the battery from the base retaining shoes at the front and right hand side. When

lifting out the battery, be aware of the considerable weight, and take all appropriate precautions to safeguard

personal health.

Reﬁt the battery, with its terminals inboard, by reversing the above procedure. Remember to push on the

breather pipe (if applicable), and reconnect the battery cables as detailed below.

Disconnecting the Battery

If the battery is to be disconnected, the following precautions should be taken:

Wait for at least ten seconds after switching off the ignition to allow the engine management system to

adjust the setting of some components ready for re-starting.

ii) If the car is ﬁtted with the upgraded security alarm, immediately before disconnection, mobilise the engine

using the transmitter button with ignition off, and disconnect the battery within 25 seconds. If disconnected

after this time, or when immobilisation is in effect, the alarm will be triggered.

iii) Ensure that all electrical loads (e.g. lights) are switched off.

iv) Disconnect the negative (earth; black; ‘-’) battery cable ﬁrst, and re-connect last. If the battery positive

terminal is inadvertently earthed (e.g. when using a spanner) whilst the negative terminal is still connected,

the resultant short circuit with heavy sparking and current ﬂow could cause serious burns.

v) If the vehicle is ﬁtted with security coded audio equipment, check that the code is available for entering

after battery reconnection.

Battery

clamp

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Lotus Service Notes

Section MP

Battery Reconnection

Check again that all electrical loads are switched off.

ii)

Connect the positive battery cable ﬁrst, followed by the negative (earth) cable.

iii) Be aware that the vehicle security alarm may be triggered by the action of battery re-connection. Have

the alarm transmitter key ready to disarm the alarm (see ‘Vehicle Security Alarm’).

iv) After reconnection, a change in the engine performance characteristics may be noted for a period whilst

the computer controlled engine management system ‘re-learns’ some of its settings.

v) If necessary, enter the security code into audio equipment.

Battery Charging

Under conditions of normal daily use, it should not be necessary to use external battery charging equip-

ment. In a low usage regime, however, it is important to maintain the charge state of the battery using a trickle

charger, or an automatic battery management charger such as that available through Lotus After Sales. Such

devices, when connected to a vehicle battery, continuously monitor battery charge state and switch on and

off automatically in order to maintain the battery in a fully charged state without danger of damage through

overcharging.

If the battery becomes discharged to the extent that the vehicle cannot be started, the recommended

course of action is to ﬁt a substitute battery whilst the original battery is trickle charged. If, in an emergency,

the vehicle has to be ‘jump’ started, the subsequent conditions of vehicle use may not allow for sufﬁcient alter-

nator charging of the battery to achieve a fully charged state. The battery should be trickle charged until 12.8

volts is recorded, which process may take 24 hours or longer. Putting the battery into service at a lower state

of charge will reduce the time period for which the vehicle can be parked. A battery left in a fully discharged

state for a prolonged period, may not be recoverable to its original condition.

Unless using an automatic battery management charger, the battery should be removed from the car for

recharging, to a well ventilated area to avoid a build up of fumes in the luggage compartment and to prevent

damage to the car's electrical system. Observe the safety precautions listed above when removing the bat-

tery and take care to avoid sharp knocks or shocks, keeping the battery as upright as possible. Beware of the

considerable weight of a battery, and take necessary precautions against personal injury.

Check that the electrolyte level is between the upper and lower markers on the battery case, and if neces-

sary add distilled water. The recommended bench charge rate is 4 amps. When the battery is fully charged

(12.8 volts), allow the battery to stand for an hour before reﬁtting into the battery well and reconnecting the

leads - see above.

Quiescent Drain

With a fully charged battery, the current drain with all electrical equipment switched off (no radio ﬁtted)

should be as follows;

Immobiliser active

15 mA

Alarm set

20 mA

If current drain is found to be signiﬁcantly in excess of these ﬁgures, the cause must be established by

isolating components (e.g. at fusebox) and rectifying faults as necessary.

Battery Cables

The main battery positive cable runs from the battery to a binding post mounted on the engine ECU plate,

itself ﬁxed to the engine bay bulkhead. From this post, one cable loops to the starter motor and then to the

alternator, and another is routed through the LH sill, ﬁxed to the outside of the chassis LH side rail together with

the heater return pipe, clutch hydraulic hose and servo vacuum hose, and penetrates the scuttle bafﬂe panel

to a second positive post mounted on the top of the scuttle beam. This post is used to distribute power to the

main fusebox and other front end circuits.

The battery earth cable connects to a chassis earth point on the inside surface of the LH chassis rail at the

side of the engine bay, accessible from beneath. From here, an earth braid connects with the ECU plate and

also with the transmission casing. A second earth point is used at the front of the chassis to provide for front

mounted components, and is located within the front services compartment on the inside surface of the chassis

LH siderail. Each chassis earth point uses an M8 threaded insert and on some cars, a special stepped washer

which must be ﬁtted the correct way round in order to contact the chassis (anodisation removed around insert).

The chassis and cable earth terminals should be coated with petroleum jelly to protect from corrosion.

On the Exige, positive and negative posts are provided on the passenger side in the front services com-

partment in order to allow for jumper cable connection on a car with a ﬂat battery, when release of the engine

cover is not available.

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