Lotus Elise / Lotus Exige. Instruction - part 102

Lotus Service Notes Section PL

Page 22

To remove heater/evaporator/fan unit:
1.

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

Remove the two air deflector/water shields, windscreen washer reservoir and ducting between heater/
a.c. unit and air distribution unit.

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

Disconnect the refrigerant pipes as necessary and remove the receiver-drier unit and mounting bracket.
Disconnect the outlet pipe from the expansion valve. Cap all pipes and ports immediately to prevent the
ingress of dirt and moisture.

Disconnect the hoses from the heater matrix and collect escaping coolant.

Unplug the wiring harness from the temperature flap motor, a.c. thermostat and fan motor.

Remove the clamping bridge retaining the unit into the chassis and release the overcentre clips securing
the unit to the fan blower housing. Withdraw the unit from the chassis together with the drain tube.

To refit heater/evaporator/fan unit:

Before refitting the unit, first ensure that the following components are fitted in the chassis:

Fresh air intake ducting/re-circulation valve assembly, retained in channel at front of chamber by single
clamp bracket. Check that re-circ. flap stepper motor harness is connected, and that the moulded plastic
water shield is fitted over the actuator.

-
-

Recirc. ducting is fitted in rear of chassis climate chamber

Earth cables are connected to chassis negative post at the left hand side of the chamber.

Rear circuit brake pipe is fitted between master cylinder and bulkhead connector.

Position the fan housing into the passenger side of the chassis chamber. Fit the drain tube into the base

of the heater/evap. unit and use a guide wire or similar to aid routing of the tube through the chassis crossmember
via the central aperture at the back of the chamber, as the unit is fitted into the chamber. Engage the lower
edges of the fan unit and heater/evap. unit before clamping together with the two overcentre latches. Retain
the assembly by fitting the bridging clamp bracket.

Continue re-assembly in reverse order to removal.

PL.12 - AIR DISTRIBUTION UNIT

The airflow distribution unit is mounted on top of the chassis scuttle, sandwiched between the underside

of the fascia top/demist duct and the chassis. The unit comprises several plastic mouldings bonded and
rivetted together to contain the rotary flap for windscreen/face level vents, and also the footwell flap. The
stepper motor for the rotary flap is mounted on the side of the unit.

To Remove
1.

Remove the front clamshell (see sub-section BR.6) and washer bottle and wiper mechanism (see sub-
section MP.8).

Remove the air trunking between the heater/a.c. unit and the distribution unit.

Release the fixings securing the heater water pipe to the chassis scuttle.

Drill out the rivets securing the distribution unit retaining bracket to the chassis scuttle.

Withdraw the unit from beneath the scuttle baffle panel, disconnecting the stepper motor harness plug
when access allows.

Lotus Service Notes Section PL

Page 23

Refit in reverse order to removal, ensuring that the sealing foam between the unit and baffle panel and on
the chassis scuttle is present and in good condition. Secure by re-rivetting the retaining bracket.

PL.13 - REFRIGERANT PIPES

The main feed and return (high pressure liquid and low pressure suction) lines to the compressor take the

form of aluminium pipes routed along the outside of the RH chassis rail, such that removal of the body sill panel
is required for access to the pipes. Replacement of the pipes is unlikely to be necessary other than as a result
of accident damage, in which case the body sill will be replaced in accordance with Service Notes Section BQ.

PL.14 - AIR BLENDER & RE-CIRC. FLAP ACTUATORS

The stepper motor (actuator) for the air temperature blender flap is mounted on the side of the heater/a.c.

casing and is secured by two screws. A moulded plastic cover is hooked over the actuator to provide protection
from direct water contamination. On installations where the actuator is on the rear of the unit (RHD Rover
powertrain; LHD Toyota powertrain), access to the actuator requires the unit to be removed from the chassis
(see sub-section PL.12).

With the heater/a.c. unit removed, pull off the moulded water shield and release the two fixings securing

the actuator to the casing. The nuts are accessible inside the casing via the air outlet aperture, but the air
blender flap may need to be moved to allow access to both nuts. In order to allow flap movement, the flap must
be mechanically disconnected from the motor by unclipping the actuator outer cover and sliding a drive gear
off its shaft.

On installations where the actuator is on the front of the unit (LHD Rover powertrain; RHD Toyota powertrain),

and the car is not fitted with air conditioning, the actuator is accessible with the unit 'in-situ'. Remove the front
clamshell (sub-section BR.6), release the harnesses from the the front edge of the climate chamber and tie
back the harnesses and water hoses to allow optimum access to the actuator. Pull off the moulded water
shield, unclip the actuator outer cover and slide off a drive gear to allow the flap to be moved for access to the
two fixing nuts inside the casing. To aid reassembly, it is recommended to glue the two fixing spacers in
position.

The re-circulation flap actuator on both RHD and LHD cars is accessible only with the heater/a.c. unit

removed. If this should occur, the re-circ. flap actuator water shield should be fitted (if not already present) by
withdrawing the re-circ. flap assembly from the channel in the front of the climate chamber, hooking the water
shield over the actuator and refitting into the chassis, noting that the actuator lead is looped downwards to
prevent water tracking along the lead and into the actuator.

Early cars built before May 2004 will benefit from the fitment of an extended clamshell gutter (if not

already fitted). On later cars, the fettling of the clamshell was revised to prevent water spilling directly into the
actuator area.

Parts Required

Part Number

Qty

Gutter Extension Panel, RHD

A117B0703K

Gutter Extension Panel, LHD

A117B0704K

Remove both front body access panels, and the two louvre panels. Remove the two air deflector panels
to which the louvre panels attach.

The rear of the radiator is secured by two pairs of screws along the top rear edge. Release the inboard
screw on each side.

Before attempting to install the new gutter extension panel, protect the top surface of the radiator with a
rigid plastic sheet or similar to avoid damage to the delicate finning. Manoeuvre the gutter extension
panel into the underside of the clamshell spine, and retain with the two radiator fixing screws. Note that
the panel incorporates a hot air dam for the spine area.

Refit the two air deflector panels, the louvres and the access panels.

Lotus Service Notes Section PL

Page 24

Hot air dam

Gutter extension panel

Radiator
inboard fixing

sb79

Lotus Service Notes Section QH

Page 1

CLUTCH

SECTION QH

Sub-Section Page

General Description

QH.1

Clutch Pedal

QH.2

Hydraulic Release System

QH.3

Clutch Assembly

QH.4

Content .. 100 101 102 103 ..