Lotus Elise / Lotus Exige. Instruction - part 101

Lotus Service Notes Section PL

Page 18

PL.8 - CONDENSER

The engine cooling radiator, a.c. condenser and cooling fans are secured together as a package and are

mounted horizontally, with fans lowermost, on top of the crash structure. The all aluminium condenser is of
parallel flow construction, with tanks at each side which direct the refrigerant flow from the front inlet connec-
tion successively through 10, 7, 5 and 4 rows, before it emerges from the rear outlet union. Bonded to the front
and rear of the condenser are steel channels which incorporate mounting brackets to attach the unit to the
lower flanges of the engine cooling radiator, and also to provide mountings for the two cooling fans.

For access to the condenser or cooling fans, the front clamshell must be removed followed by the radiator

mounting panel with the complete cooling pack.

Remove the front clamshell (see sub-section BR.6).

Remove the two air deflector/water shields.

Drain the coolant and disconnect the feed and return hoses from the radiator.

Unplug the fan harness connector(s).

Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.

Using two spanners on each connection to avoid twisting the union, release the two refrigerant pipes from
the condenser and immediately cap both the pipes and the condenser unions to prevent the ingress of dirt
and moisture.

Engine cooling radiator

Front spreader plate

Rear
mounting

Front mounting

bracket

Radiator

a.c. condenser

mounting
panel

Cooling fan

p106

Lotus Service Notes Section PL

Page 19

Front mounting
spreader plate

Rear mounting
spreader plate

Radiator
mounting
panel

Front
mounting
bracket

Rear
mounting
bracket

Engine
cooling
radiator

Air conditioning
condenser

Fan fixing

Cooling fan

p105

Lotus Service Notes Section PL

Page 20

Release the radiator mounting panel from the crash structure and lift away the complete assembly.

To remove the radiator pack from the mounting panel, pull out the sealing foam, release the three bolts
securing each rear bracket to the panel, and the two bolts fixing each front bracket to the panel. Separate
the fans, condenser and radiator as necessary.

On re-assembly, note that the two angle brackets securing the rear of the condenser to the radiator duct,
are positioned below the condenser flange, and use a spacer washer at the adjacent fixing point to
replicate the flange thickness. Ensure that the sealing foam is refitted around the sides and rear of the
condenser, and that the spreader plates are fitted on top of the housing at the front fixing points.

10.

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.

Using two spanners, tighten the condenser inlet connection to 25 - 30 Nm.

Using two spanners, tighten the condenser outlet connection to 20 - 25 Nm.

Recharge the system with 0.55 kg of R134a.

Refill the cooling system (see sub-section KH.3).

PL.9 - RECEIVER-DRIER

If the system has been open to at-

mosphere for any length of time, e.g. fol-
lowing 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 at the front of the climate
chamber. If the receiver-drier is to be re-
placed, the refrigerant must first be recov-
ered using suitable equipment connected
to the service ports at the right hand front
of the engine bay.
-

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

When reconnecting the pipes, use
new 'O' rings coated in an approved
refrigerant oil, and tighten to 20 - 25
Nm.

PL.10 - EXPANSION VALVE

The expansion valve is fitted onto the evaporator inlet and outlet pipes above the climate chamber, and

is accessible from within the front services compartment. To replace the valve:

Recover the refrigerant using suitable equipment connected to the service ports at the right hand front of
the engine bay.

Release the single M6 screw securing the clamp plate to the top of the expansion valve, and withdraw the
plate and both pipes from the valve. Immediately cap the pipes and ports to prevent the ingress of dirt
and moisture.

Radiator mounting panel

Inlet connection

Trinary switch

p107

Outlet
connection

Mounting

Receiver

Windscreeen

bracket

drier

Lotus Service Notes Section PL

Page 21

Release the two M5 screws from the counterbored holes in the top of the valve, securing the valve to the
evaporator pipes, and withdraw the valve from the pipes. Immediately cap the pipes and ports to prevent
the ingress of dirt and moisture.

Before refitting, renew all the connector 'O' rings, and coat with an approved refrigerant oil.

Fit the threaded clamp plate around the evaporator pipes, and secure the expansion valve onto the pipes
with the two M5 screws tightened to 5 - 6 Nm.

Use the second clamp plate to secure the two pipes to the expansion valve, tightening the single M6
screw to 7 - 9 Nm.

Recharge the system with 0.55 kg of R134a.

PL.11 - HEATER/EVAPORATOR/FAN UNIT

The heater matrix and a.c. evaporator are contained within a single housing together with the air blender

temperature control flaps. The housing is mounted in the chassis climate chamber where it is clipped to the fan
blower unit, and retained by a simple clamp bracket.

Note that the heater/a.c./blower unit is fitted the opposite way round between Rover and Toyota powertrain

cars: On 'Rover' cars, the blower unit is on the passenger side, and the air blend actuator on the rear of RHD
installations, and in front on LHD. On 'Toyota' cars, the blower is on the driver's side, and the air blend actuator
on the front of RHD cars and the rear of LHD.

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

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