Lotus Eleven/Elise/Exige. Instruction

Lotus Service Notes Section WD

Page 19

Removal of Seat Belt Assembly

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withdrawn, and the battery leads disconnected from both positive and negative terminals, and iso-
lated to ensure that accidental contact cannot occur.

Each seat belt reel assembly is secured, via a spacer block, to the seat belt mounting bracket/roof hoop

by a single bolt. Note that an orientation tang is incorporated on the belt reel which engages with a hole in the
spacer, and that the spacer is keyed to the mounting bracket by a roll pin.

Check that the key is removed from the ignition switch.

Disconnect both battery cables, and insulate to ensure that accidental contact cannot occur.

Remove both seats by releasing the seat belt from the seat (noting the 10mm spacer), and the seat
runners or frame from the floor.

Remove the centre tunnel rear cup holder liner after removing the single screw from inside the base.
Remove the two screws then exposed securing the cup holder, and remove the holder, disconnecting the
auxiliary power socket.

Remove the 4 fixings along the top of the cabin rear bulkhead trim panel, and withdraw the panel,
disconnecting the speakers and interior lamp.

Hinge up the plastic cover and release the belt slide from the roof hoop, noting the 5mm spacer.

Allow at least one minute from disconnecting the battery before disconnecting the electrical connector
from the gas generator on the seat belt assembly. Release the Torx head fixing bolt and withdraw the belt
reel assembly and spacer block.

Fitment of Seat Belt Assembly

Each seat belt reel assembly is secured, via a spacer block, to the seat belt mounting bracket/roof hoop

by a single bolt. Note that an orientation tang is incorporated on the belt reel which engages with a hole in the
spacer, and that the spacer is keyed to the mounting bracket by a roll pin.

Fit the seat belt reel assembly and alloy spacer to the bracket on the mounting frame, with the spacer

block located by its roll pin into the hole in the bracket, and the belt reel tang located in the upper hole in
the spacer. Fit and tighten the single Torx head fixing bolt (discarding the cardboard retaining washer if
fitted) to 45 Nm (33 lbf.ft). Plug the harness connector plug into the gas generator on the belt assembly.

Fit the belt slide to the roof hoop with the 5mm spacer interposed, and tighten the special shouldered bolt

to 45 Nm (33 lbf.ft). Check that the hoop is free to pivot. Clip the plastic cover into position.

Refit the cabin rear bulkhead trim panel, connecting the interior lamp and speakers, and retain with the

four screws.

Refit the cup holder, connecting the power socket, and liner.

Refit the seats and fit the seat belt to the seat frame with the 10mm spacer between belt and seat. Tighten

the special shouldered bolt to 33 Nm (24 lbf.ft). Check that the belt eye is free to pivot.

Reconnect the battery, turn on the ignition, and check that the airbag tell tale lamp lights for a few seconds

and then goes out.

Lotus Service Notes Section WD

Page 20

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
pyrotechnic charge will occur.

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

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, there-

fore, 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!

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.

Lotus Service Notes Section WD

Page 21

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 Elise 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.

Page 1

Lotus Service Notes

Exige S/C

SUPPLEMENT

EXIGE SUPERCHARGED (S/C)

Sub-Section Page

Concept & Overview

Exige S/C.#

Technical Data

Exige S/C.TD

Body

Exige S/C.B

Front Suspension

Exige S/C.C

Rear Suspension

Exige S/C.D

Engine

Exige S/C.E

Wheels & Tyres

Exige S/C.G

Brakes

Exige S/C.J

Cooling

Exige S/C.K

Maintenance & Lubrication

Exige S/C.O

Clutch

Exige S/C.Q

Miscellaneous

Exige S/C.Z

Lotus Eleven/Elise/Exige. Instruction - part 123