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Lotus Evora. Instruction - part 92

Lotus Service Notes

Section WF

WF.11 - PASSENGER AIRBAG MODULE

WARNING: Safety precautions must be observed when handling a deployed airbag. After deployment,

the airbag surface may contain a white packing powder used to ease deployment. Always wear gloves

and safety glasses when handling a deployed inflator module, and wash your hands with a mild soap

and water afterwards.

The passenger's airbag (or inflator module) is mounted on the underside of the main fascia panel and

also braced to the rear face of the chassis scuttle beam. An airbag 'door' in the top surface of the fascia, is

designed to break open under the force of airbag deployment, and, hinging at its front end, direct the inflating

bag into the area of optimum effectiveness.

The passenger's airbag (or inflator module) comprises:

an inflatable fabric bag;

an inflator (canister of gas generating material)

an initiator (or 'squib')

When the vehicle suffers a forward deceleration which closes the safing sensor, and the signal from the

SDM accelerometer or either of the two forward sensors indicates that the severity is sufficient to require airbag

deployment, current flows through the stage 1 or stage 2 deployment loop of both the driver and passenger

airbag module initiators and ignites the gas generating material. Each bag inflates in a fraction of a second, the

passenger's bag bursting open the fascia airbag door, and then deflates via vents in the bag, with the whole cycle

taking less than one second. The airbag is designed for a single deployment, and must then be renewed.

To replace passenger airbag

WARNING: The following procedures must be followed in the order listed to temporarily disable the

airbag system whilst working in the immediate vicinity of an airbag. Failure to follow this procedure

could cause unintended airbag deployment, resulting in personal injury and unnecessary airbag sys-

tem repairs.

i). Turn off the ignition.

ii). Before disconnecting the battery, use the Lotus TechCentre to read any stored trouble codes.

iii). Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the

battery negative terminal can be made.

iv). Wait for at least 30 seconds to allow the SDM capacitors to discharge.

v). Open the glovebox, release the tether and damper cords, and lower the glovebox fully.

vi). Remove the glovebox back panel; remove the two screws into the underside of the fascia panel, and prise

out the four 'fir tree' fasteners. Disconnect the glovebox lamp.

vii). Access is now available to unplug the airbag harness yellow connector.

1. Replacement of the passenger airbag requires that the main fascia panel be removed - refer to sub-section

VE.8.

2. Release the four fixings securing the airbag module to the underside of the fascia.

WARNING: When carrying a live airbag module, make sure the top surface of the module is pointed

away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of

injury. When placing a live airbag module on a bench or other surface, always arrange for the deploy-

ment face to be uppermost. This is necessary so that a free space is provided to allow the airbag to

expand in the unlikely event of accidental deployment.

3. If an airbag deployment has occurred, the chassis scuttle beam and main fascia panel must be carefully

examined for damage or distortion and replaced if necessary. The airbag door will always need replac-

ing.

Lotus Service Notes

Section WF

WARNING: Proper operation of the SRS system requires that the vehicle structure remains in its origi-

nal production configuration. Any damage to the SRS components and/or their respective mounting

brackets, including the chassis, requires replacement, not repair.

4. Fit the airbag module to the fascia panel and tighten the four M6 nuts to 10 Nm.

5. Fit a new airbag door to the fascia panel and tighten the two M6 nuts to 10 Nm. Ensure the 2 plastic barb

clips are correctly engaged.

6. Refit the fascia panels (see section VE) and plug in the passenger airbag harness connector.

7. When all service work is complete, check that the airbag tell tale lights for a few seconds with ignition, and

then goes out.

WF.12 - SEAT BELT PRE-TENSIONERS

WARNING:

•

Failure to comply with the instructions, safety standards and operating procedures as described

in this section, may cause vehicle damage and/or personal injury.

•

Both driver and passenger front seat belt assemblies must be replaced after SRS deployment. Do

not attempt to repair or reuse.

Device Operation

Initiated at the same time as the airbags, is a pyrotechnic device on each front seat belt reel assembly to

apply a tightening force to the belt reel and remove any slack from the belt. The force sustained by the belt and

its user during the event, is then controlled by a torsion bar within the belt reel to limit the deceleration force to

which the occupant is subjected. When airbag/pre-tensioner triggering conditions apply, the SDM signals igni-

tion of a gas generator on each front seat belt assembly, the pressure from which forces a train of balls around

a tubular track to apply a retraction force to the belt reel.

Lotus Service Notes

Section WF

The belt pre-tensioning mechanism is designed to operate only once, such that both front belt assemblies

should be renewed after airbag/seat belt pre-tensioner deployment. Activation of the pyrotechnic mechanism

is indicated by the belt reel being locked, and allowing neither extraction nor retraction of the belt.

To replace front seat belt assembly

Each front seat belt reel assembly is secured to the seat belt mounting frame/roof hoop by a single bolt,

with an orientation tag on the belt reel engaging with a slot in the mounting plate.

WARNING: Before removing or refitting a pyrotechnic seat belt assembly, the ignition key should be

withdrawn, and the battery leads disconnected from both positive and negative terminals, and isolated

to ensure that accidental contact cannot occur.

1. Remove the rear quarter trim panel (refer to sub-section VE.11).

2. Unplug the vehicle harness from the belt tensioner initiator, and release the belt reel assembly retaining

bolt.

3. Refit in reverse order to removal, tightening the belt reel securing bolt to 33 Nm.

4. When all service work is complete, check that the airbag tell tale lights for a few seconds with ignition, and

then goes out.

Safety Standard

The pre-tensioning function is energised via pyrotechnic materials, therefore manipulation, handling and

storage MUST be performed to the specified procedures as described to avoid any occurrence of injury to the

operator or damage to the pre-tensioning unit.

In normal conditions, the pre-tensioner assembly can only be activated through the action of the electric

ignition control during impact. During the activation phase of the pyrotechnic charge, small gas quantities are

developed. The main constituent of the gases is Nitrogen:

Note! This gas is not toxic.

The pre-tensioner assemblies must be protected against exposure;

To temperatures over 90°C (195°F) at contact with surfaces

90°C during 106 hrs.

From sparks and naked flames.

WARNING: If exposed to temperatures in excess of 140°C, self-ignition of the pyrotechnic charge of

the gas generator may occur. Exposure to temperatures in excess of 165°C, self-ignition of the pyro-

technic charge will occur.

Also, if exposed to temperatures between 90°C (285°F) and 165°C (330°F), deterioration of the pyro-

technic charge ignition is possible. The consequences of this could be failure to activate at prescribed levels.

The pre-tensioner must be protected against stresses, shocks and dropping. Pre-tensioners that have been

subjected to such treatment must be discarded and returned to the supplier with accompanying paperwork

describing the reasons for return.

Never store pre-tensioner assemblies with other flammable or combustible materials. Gas generators

MUST be prevented from coming into contact with acid, water, grease and heavy metals:

Contact with these

substances may cause toxic or dangerous gases, or explosive mixtures.

Any residual fuel of the gas generator, not burned during ignition, is slightly flammable. The unit, therefore,

must

never be disassembled, damaged or the parts manipulated. Any advertising or demonstrations of the

pre-tensioner assembly should only be carried out using inert pre-tensioners (without the pyrotechnic charge).

The base of the pre-tensioner must be painted green, with visible and indelible wording, stating

‘Inert Assem-

bly’. It must incorporate the KSS logo, signed with indelible ink by the person responsible for the supply of the

product.

WARNING: Never disassemble the pre-tensioner or any of it’s components!

Lotus Service Notes

Section WF

Transportation of belt with pre-tensioner

Transport on road vehicles should be carried out with the assemblies stored in the luggage compartment.

Never transport in the passenger compartment. Never transport the pre-tensioner instructionly or holding it by the

webbing: this can result in damage to the assembly.

Storage of belt with pre-tensioner

Belts with pre-tensioning elements should be stored in containers or boxes that can be locked with a key,

and ventilated. They MUST be stored in an area free from flames and heat sources. On completion of work,

or during work break periods, pre-tensioner belts should be returned to the storage container and locked with

a key.

Disposal of belts with pre-tensioner

Charged pre-tensioners to be scrapped and not fitted to a car must be activated. This should be carried

out only by the belt manufacturers, or specialised workshops.

Vehicle disposal

Charged pre-tensioners fitted to a vehicle MUST be removed before the vehicle is dismantled for scrap-

ping. If the pre-tensioner is not activated during an accident, the device must be considered as still to be in a

'charged' condition.

General safety instructions/dangers for health

When handling activated pre-tensioners, use safety glasses and vinylic or nitrylic protection gloves.

After handling a loaded pre-tensioner, wash hands with soap and water.

There is no danger of exposure to propellants in the sealed system. The propellant mix is in a solid state,

therefore no inhalation is possible, even if the gas generator cartridge is broken.

Avoid skin contact and do not ingest the propellant.

First aid

Ingestion: Help the person vomit if conscious. Call a physician.

Skin contact: Wash immediately with soap and water. Call a physician.

Eyes: Wash the eyes immediately with running water for a minimum of 10 minutes. Call a physician.

Inhalation: Take the person immediately to fresh air. Call a physician.

General notice

Storage, transport, dismantling and/or recycling of the pre-tensioner shall be carried out according to the

legal and local regulations, taking account also of directives for masonry, fire fighting, transport, environmental

protection and the safety and health of all staff.

WARNING: The seat belt pre-tensioner devices fitted on the Lotus Evora are designed and calibrated

specifically for this particular model. Pre-tensioners must not be adapted, re-used or installed on any

other vehicle - they must only be fitted to the prescribed vehicle with specific homologation continu-

ity.

Any attempt to re-use, adapt or install pre-tensioners on a different vehicle can cause severe or fatal

injuries to the occupants during normal operation as well as the result of an accident.

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