User manual LOTUS ELISE BODY FITTINGS BP 2001

[. . . ] Vacuum Pipes, Valves, Flaps, Actuators, Vacuum Pump Intake Plenum, Ducting Outlets & Vents Labels & Literature 19. 01A 19. 03A Labels Owner's Handbooks & Service Notes Manuals Suspension 31. 01A 31. 03A Front Suspension & Hubs Rear Suspension & Hubs Steering 32. 03A 32. 05A Power Steering Rack, Lower Column Upper Steering Column & Wheel, Lock & Ign. Switch Brakes 33. 01A 33. 01B 33. 01C 33. 03A 33. 03B 33. 05A S4 Prior VIN*: Brake Calipers & Discs S4 From VIN*: Brake Calipers & Discs Sport 300: Brake Calipers & Discs Booster/Master Cylinder, Pump, Accumulator Hydraulic System, Brake Pipes & Hoses Parking Brake Mechanism Engine 40. 01A 40. 03A 40. 05A 40. 07A 40. 09A 40. 11A 40. 13A 40. 15A 40. 17A 40. 19A 40. 21A 40. 23A 40. 25A 40. 28A 40. 28B Block, Main Bearing Housing, Engine Mountings Oil Sump Cylinder Head & Gasket, Valves, Guides & Springs Cam Housings, Camshafts, Tappets Pistons & Liners, Connecting Rods Crankshaft, Flywheel Water Pump Auxiliary Housing, Oil Pump, Turbo Oil Pipes D. I. Leads, Spark Plugs Alternator, Starter Motor Exhaust Manifold, Turbocharger A. C. Compressor, Mounting Bracket, Jocky Wheel Power Steering Pump, Pulley, Mounting Bracket Engine Upper Gasket Set Engine Lower Gasket Set Belts & Pulleys 41. 01A 41. 03A Camshaft Belt, Toothed Pulleys, Tensioner Auxiliary Drive Belts & Pulleys Induction System 42. 01A 42. 07A Airbox, Chargecooler, Intake Plenum Inlet Manifold, Fuel Rail, IAC Valve Fuel System 44. 01A 44. 03A 44. 05A Fuel Tanks, Filler Necks, Gauge Sender Unit Fuel Pump, Filter, Fuel Pipes Evaporative Loss System Exhaust System 45. 01A 45. 05A Exhaust System & Mountings, Ex. [. . . ] A noticeable change in pedal feel (to a hard pedal) will occur when the accumulator is completely discharged. Release the reservoir cover, and use a syringe to remove as much fluid as possible from the reservoir, Discard fluid. Page 56 3. 4. Protect the surrounding area of bodywork and electrical connections from fluid drips when the reservoir is removed. Use a suitable container or shop towel to catch fluid, and disconnect from the reservoir the fluid supply hose from reservoir to pump assembly. Use a Torx spline wrench to release the three screws inside the reservoir, securing the reservoir to the master cylinder assembly, and carefully lift the reservoir off the solenoids. , Reservoir retaining screw RH front solenoid 5. Outlet to punp assembly Haster cylinder reservoir port Rooster return port . Rear solenoid Reservoir retaining screws Pressure' relief valve LH front solenoid 6. Before re-fitting the reservoir, thoroughly inspect the solenoid seals for damage, and correctly position Yt the reservoir sealing gasket on the master cylinder assembly. Carefully fit the reservoir over the solenoids, and fit the three securing screws. Refit the low pressure hose to the reservoir, and connect the low fluid level switch. Refill the reservoir with new DOT 4 fluid and bleed the system as in JF. 8. 7. 8. 9. JF. 16 - SOLENOID VALVES The solenoid valves, one for each front circuit and one for the combined rear circuit, may be removed from the master cylinder/booster assembly after removing the fluid reservoir. Unplug the electrical connector from the solenoid, and use a Torx spline wrench to remove the two solenoid retaining screws. Withdraw the solenoid. Page 57 Pressure relief valve Reservoir Low fluid level sensor Reservoir gasket Rear solenoid RH front solenoid LH front solenoid Bleed nipple \ , Bleed nipple 3. Before refitting the solenoid, check that both `0' rings on the lower end of the solenoid are in place and in good condition. Torque tighten to 33 Nm (25 Ibf. ft). Page 59 Master cylinder/ booster assembly Plastic circlip \ Pushrod nose \ Pushrod Pushrod boot \ Root retaining plate Spacer Bulkhead gasket * \ Mounting bracket steady . accumulator Reinforcing plate Bulkhead movnting bracket Clutch master cylinder / . , Jy@T 3 brake circuit brake circuit Rear brake circuit Clutch pipe - 3. Before adjusting the brake pedal pushrod length, first remove the stop light switch (twist % turn counterclockwise) and adjust the brake pedal height. as shown in the diagram, and adjust the pedal upstop to achieve the specified dimension: cars prior to `92 M. Y. : 205 - 215 mm cars `92 M. Y. onwards: 160 - 170 mm Check that the brake pedal pivots freely and does not stick or bind. I , Pedal ups top H Brake lights switch \ \ , 2mm Free play Prior `92 M, Y: 205 - 215 mm ICI- IV/. . I --_ IOU - 4vn-. I on: 4L-n I/ UIIIIII -Yz 7Omm primary travel 4. Adjust the effective length of the pushrod by screwing the pushrod nose in or out of the pushrod until the clevis pin can be fitted freely without preloading the pushrod - the pedal should `rattle' with a few millimetres of free play. Check that the pedal travels about 10 mm before a noticable increase in resistance. Fit the brake light switch into its mounting bracket, and set so that when twisted % turn clockwise to retain, there is about 2 mm of the white plunger visible. Note that the ABS requires a signal from the stop switch as an indication of brake application before the system will operate. Fit the two front brake pipes (Ml2 & Ml3 thread) and the single rear brake pipe (Ml4 thread) to the master cylinder/booster assembly. Tighten all unions: Ml2 - 23 Nm (17 Ibf. ft) Ml3 - 25 Nm (18 Ibf. ft) Ml4 - 27 Nm (20 Ibf. ft) Fit the high pressure supply pipe (Ml0 thread) from the accumulator to the master cylinder/booster, and torque tighten to 14 Nm (10 Ibf. ft). Reconnect the harness to the low fluid level switch, and to the three solenoids. 5. 6. 7. 8. Fill the reservoir with DOT 4 fluid and bleed the brake system (see section JF. 8). Page 61 JF. 18 - PUMP/ACCUMULATOR ASSEMBLY The pump/accumulator assembly is located . at the right hand side of the front luggage compartment. [. . . ] @ Qty 1 Function Code 47. 01 Clutch & Release Mechanism Part Description Clutch master cylinder 5/8" Push Rod, clutch master cylinder Clevis, pushrod Locknut, pushrod to pedal to clevis 02 03 04 04a 05 06 07 08 08a 09 10 11 1 1 2 1 1 Clip, pushrod retention Clevis Pin, clevis to pedal `R'. Clip, pin retention Washer, wavy, pin tensioning Clutch pipe assembly, front LHD Clutch pipe assembly, front RHD Connector, clutch pipe to master cylinder Washer, flat, 3/8", copper Grommet, pipe through chassis Nyloc Nut, M8 Washer, flat, M8 x 16 Clip, pipe fixing Clip, double, pipe fixing Braided Hose, bundy to slave cylinder 2 1 1 1 1 3 2 2 12 13 14 15 1 1 16 Function Code: 47. 01, Page: 1 Function Code 47. 01 Clutch & Release Mechanism m P a r t Description 17 18 19 20 21 22 23 24 25 28 27 28 29 30 31 31a 32 33 34 35 Slave cylinder Bleed nipple Push Rod, slave cylinder Slave Cylinder Mounting Bracket Bolt, bracket to bell housing Washer, flat Setscrew, M8 x 25, hex. slave fixing Washer, spring Clutch master cylinder Screw, M8 x 20, cap. black, master cylinder to pedal box Washer, spring, M8 Clevis Pin Washer, flat, nylon Clip, pin retention Clutch pipe assembly, front LHD Clutch pipe assembly, front RHD Clutch pipe, main Hose & Pipe assembly Clip, clutch flex pipe/main pipe Clutch flexpipe bracket V8, prior to `98 MY V8, prior to `98 MY V8, V8-GT, `98 MY on Remarks Option V8, prior to `98 MY V8, prior to `98 MY V8, prior to `98 MY V8, prior to `98 MY Part Number A082Q6031 F A082Q6025F A082Q4031 A91 8E0216K A075W1039Z A075W4020Z A075W1039Z A075W4036Z A082Q0724F A111W7l30F A075W4032Z A082Q0727F A082Q0714F A082Q0728F A082Q0730K A082Q0729K A082Q4069K A082Q0725F A082Q0728F A082Q4071 F 1 2 1 1 1 1 1 1 1 F 1 3 3 2 2 1 2 m! 1 1 V8, V8-GT, `98 MY on V8, V8-GT, `98 MY on V8, V8-GT, `98 MY on V8, V8-GT, `98 MY on V8, V8-GT, V8, V8-GT, V8, V8-GT, V8, V8-GT, `98 MY on `98 MY on `98 MY on `98 MY on V8, V8-GT, `98 MY on V8, V8-GT, V8, V8-GT, `98 MY on `98 MY on Function Code: 47. 01, Page: 2 Function Code 47. 01 Clutch & Release Mechanism Dep Part Description Remarks Option Part Number A079J6020F A082Q0726F A082Q4059K A075W2037Z A075W4032Z A075W4020Z A111W116 6 F A082Q4072K A082Q4060K A082Q4042H Qty 1 36 37 38 39 40 41 42 43 43a 44 45 45a 46 47 48 49 50 51 52 53 54 Connector, clutch pipe Slave cylinder Slave Cylinder Mounting Bracket Screw, M8 x 30, hex. 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