Lotus Cars Service Bulletin 2000/1

Introduction to the 340R.

Service bulletin issued March 2000

TITLE   Introduction of Elise 340R.

REASON:   To advise features and specification.

CONCEPT  

The Elise 340R is based on the standard Elise chassis, but uses completely different bodywork and interior, and a detuned, road going version of the Rover VHPD powertrain.  The car embodies the original philosophy of the Elise, with performance achieved through light weight and efficiency, but is taken to a further extreme to focus on driving pleasure, and is aimed at the enthusiast driver and for use on track days.  This bulletin summarises the principal features of the car, and the areas in which the specification differs from the standard Elise: 

IDENTIFICATION

Character 13 of the V.1.N. identifies the model: '3' Elise., '6' = 340R.  Note that a common serial number sequence is used for all Elise variants, but recommences at 0001 for the 2000 model year, and similarly for each subsequent new model year (character 10).

 CHASSIS

The bonded aluminium alloy chassis structure is derived from the standard Elise chassis, but has no door hinge mountings, and the sill top edge support flanges are replaced by channel strips to mount the cockpit side screens.  The galvanised steel rear subframe is fitted with additional weldnuts, and has been commonised for the standard Elise.  No chassis rear longerons are used, but a thick machined alloy plate is bolted to each rear corner of the subframe to support the carbon fibre rear aerofoil.  The special roll over bar comprises individual hoops for driver and passenger, interlinked to form a crossbraced structure, fabricated from oval section steel tubing, with back stays anchoring to the rear aerofoil mounting plates.  The composite front crash structure is revised to accommodate the new body, and is supplemented by a new aluminium front undertray which incorporates longitudinal rivetted box sections.

BODY

The non-structural composite body structure is minimalist and functional, with the exceptionally light weight contributed to by the exclusion of opening doors or a roof structure.  The principal body mouldings are as  follows:

 Cockpit Tub: Single piece moulding includes the scuttle, cockpit coaming and rear bulkhead.  Bonded to the chassis with elastomeric adhesive.

Side Closing Panels: Closing panel between outboard top edge of tub, and top of chassis side rail, extending rearwards to form the engine bay side walls and to provide support for the topshell.

Cockpit Side Screens: The cockpit sides are made from translucent polycarbonate sheet, bonded to the chassis and upper side panels.

Topshell: Single piece moulding includes the whole nose section, cockpit surround and rear body deck.  Secured with threaded fasteners.  Incorporates two removeable access panels at the front, each of which is secured by four threaded fasteners.  The engine lid at the rear is fixed by nine threaded fasteners.

Sill Panels: Run from behind each front wheel to sweep upwards ahead of the rear wheels.  Bonded to the chassis with elastomeric adhesive.

Front SpoilerlSplitter.. One piece moulding bolted to the topshell, includes splitter panel beneath nose and twin deck aerofoils ahead of each front wheel.

Windscreen Frame: One piece composite moulding similar in concept to standard Elise, but excludes fascia top, and accommodates a shorter windscreen.

Engine Bay Rear Wall: Composite panel bolted to topshell.  Removeable for competition use.

Rear Shroud: Composite panel protects silencer and supports rear diffuser Bolted via brackets to the rear subframe.

Rear Aerofoil: Carbon fibre moulding bolted between alloy support plates.

Mudguards:      Separate, close fitting composite mudguards are used on each wheel, mounted to the hub carrier.

SUSPENSION & BRAKES

The 340R is fitted with the Elise Sport suspension package which includes adjustable spring platform Koni dampers with the shorter and stiffer springs, and the uprated front anti-roll bar in Nylon chassis mounting blocks.  Standard Elise wishbones are used, with standard 'integral stud' ball jointed toe-links on the rear.  All cars use the forged steel rear hub carriers.

Two variations of suspension geometry are specified; one for road use (with Yokohama or Pirelli tyres); and one optimised for track use with increased negative camber and toe settings.  Ride height for both applications is common at 100mm front and 110mm rear, with sport kit steering rack positioning plates factory fitted.

ENGINE

The 340R engine is the VHPD version of the Rover 1.8 K series in (132.5kw/177 bhp/180.4ps) road tune.  Engine management is based on that used for the Lotus type 918 V8 engine, with that engine's electronic controller, ignition coil pack, and other engine management components.  For engine management diagnosis, the 'Tech 1' tool should be used with the V8 cartridge T000T1307F, referring to fault codes as listed in Service Notes Manual Section EMM (L082T0327J).  The codes applicable to the 340R are listed in the service notes supplement.

Other new features of this engine include a revised, higher efficiency, inlet manifold/throttle body, shorter than that used previously on the 190, and an increased volume intake air box, fed with air via a trunking terminating at the left hand bottom corner of the engine bay. 

Resonator Valve: Incorporated in the intake trunking is a resonator butterfly valve which is controlled by the engine management system, and is designed to suppress intake noise under certain engine operating conditions.  The valve is spring loaded to the normally open position, but is closed by vacuum when accelerating with wide throttle through the lower gears at about 30 - 40mph.

 Air Cleaner.. The Elise 340R uses two identical conical foam air cleaner elements contained within the air intake trunking; a primary filter mounted at the inlet end of the trunking; and a secondary filter mounted immediately after the resonator valve. When the vehicle is operated in a relatively clean environment, the primary filter should be cleaned every 'A service, and the secondary filter every 'B'service, but where a dusty or smog laden atmosphere prevails, more frequent servicing will be required dependent on the level of pollution.

When removing either filter, take care not to contaminate the engine side of the duct or airbox with dirt.  Follow the filter manufacturer's cleaning instructions..

1 .         Dislodge any large embedded dirt by tapping the filter gently.  Brush with a soft bristle brush to remove other dirt.

2.       Spray Pipercross foam air filter cleaner liberally onto the entire filter.  Let soak for 10 minutes.

3.       Never use other cleaning agents e.g. gasoline, caustic strong detergents or solvents.  Never use steam cleaners or a high-pressure car wash.  Doing so will invalidate the warranty.

4.       Rinse off the filter with low-pressure tap water from the clean side to the dirty side.  This will remove dirt and not drive it into the filter.

5.       Always let excess water drain from the filter Let the filter dry naturally.  Never use compressed air; open flame or hot air dryers.

6.       After cleaning the filter, Pipercross Dirt Retention Additive (DRA) must be re-applied.  Pipercross DRA is a very efficient high tack polymer.  Never use motor oil, diesel fuel, ATF or WD40.

7.       Re-install the filters and intake ducting.

 Exhaust System: The 34OR engine uses a special exhaust manifold fabricated from 45mm diameter steel tube leading via a flexible section to the standard catalytic converter and then into a new transverse muffler.

TRANSMISSION

A close ratio transmission with 4.2.-1 final drive is used, in common with the Elise 111 S. 

INTERIOR

The interior continues the minimalist theme of the standard Elise, but shares few components with the standard car:

- The fascia top is scalloped to a lower level, meeting the chassis scuttle beam, from which an alloy cockpit divider extends downwards to the floor.  A curved instrument mounting rail, of composite construction extends across the fascia, and houses the speedo and tacho.  The cockpit divider is used to mount a vertical row of push button switches.

- Special lightweight composite seats are trimmed in Alcantara suede and leather, with carbon effect leather reinforcement patches.

- 4-point seat belt harnesses are provided for both driver and passenger, with a race approved 5th point adaptor kit available if required.  The buckle is attached to the outboard lap strap, with other straps plugging into appropriate slots in the buckle.  A single press of the red button on the buckle releases all straps.  The FIA approved competition adaptor kit includes a crutch strap and a twist release buckle. - The two instruments include the various tell tale lamps, with the speedo also including an LCD panel to display fuel quantity by bar graph, a digital coolant temperature display, and a total distance and trip recorder. - The vertical row of switches in the cockpit divide houses push switches for the following functions, listing downwards: panel illumination/trip reset; side marker lamps; headlamps; rear fog; heated windscreen.  The hazard warning switch in sited between the two instrument, and a starter button is positioned in the centre of the fascia.

- The heated windscreen operates (when requested) only when the engine is running, and for a maximum time period of 15 minutes. - Two auxiliary power sockets are provided at the rear of the cockpit centre divide, to accommodate heated (motorcycle type) suits, or similar equipment.  The sockets are powered only when the engine is running at over 2,000 rpm, with a maximum allowable current draw of 15 amps from each.

- A rudimentary heater is provided in the form of a hot air duct linking a portion of the engine radiator outlet airflow to a driver's footwell vent.

SECURITY

As the 340R uses a Lotus engine management controller, the security system (Lucas 5AS) used on the standard Elise is not fitted.  In its place, a Meta security system is used as either an electronic immobiliser meeting Thatcham category 2 requirements, or, as an optional upgrade, a full alarm system incorporating cockpit intrusion sensing and a self powered siren, which meets Thatcham 1.

Full details of the security system are contained in the Elise Service Notes 340R Supplement, but in summary: Passive Immobilisation will be activated 20 seconds after switching off the ignition, and is indicated by the alarm LED sited centrally on top of the fascia blinking once every 2 seconds.  To mobilise the engine, press once the button on the transmitter key.  Mobilisation will be acknowledged by the tell tale going out.

To Arm the Alarm: Press the transmitter button for about 2 seconds.  This command will be acknowledged by: - Two flashes of the hazard warning lamps;

- The tell tale on the fascia top lighting, and blinking off once a second.  After a set-up period of 25 seconds has elapsed, the tell tale blink pattern will invert; becoming mainly off and blinking on once a second.

Check that these indications occur.  If not, press the button a second time, as the first press may have only switched off the passive immobilisation (see above).

To Disarm the Alarm: To disarm the alarm prior to entering the vehicle, or if the alarm has been triggered, press once the button on the transmitter key.  This command will be acknowledged by: - One flash of the hazard warning lamps;

- Extinguishing of the alarm tell tale on the fascia top.

If the vehicle battery is to be disconnected on a car with an upgraded alarm;

- Before disconnecting the battery, ensure that the alarm system is disarmed.

- On reconnection of the battery, the alarm will automatically be set.  Have the transmitter ready to disarm.

ELECTRICAL

Fuses & Relays

The main fusebox is located in the passenger footwell. and is protected by a clear plastic cover.  Twenty two slots are provided for 'Littel' type fuses, which are numbered and coloured according to their amperage rating.  A relay block adjacent to the fusebox houses eight relays, with a further two relays located nearby.

Engine management fuses, relays and diagnostic connector plug, are mounted on the cabin rear bulkhead protected by an access panel retained by threaded fasteners. Fuses

Slot           Rating                   Circuit

1                 20A             Fuel pump, injectors

2           3A             Engine management, OBD2

3           7.5A             Engine management, canister purge, idle control

4           7.5A             Ignition coil

Relays

·a        Engine management ignition supply

· b        Starter solenoid

· c        Fuel pump, injectors

The main alarm system fuse is located in an individual fuse holder near the battery.

If any fuse is found blow repeatedly, no repair should be attempted until a Lotus dealer or competent auto electrician has been consulted.  Upgrading a fuse rating, or interchanging any of the relays or modules, could result in permanent damage to a circuit or electrical component.

Fuse colours:

2A - Black;                                5A - Orange;                                15A - Light Blue;

3A - Violet;                                7.5A - Brown;                                20A - Yellow;

4A - Pink;                                1 OA - Red;                                25A - Clear.

   Wheelbase   2300 mm

   Track - front   1432 mm

                - rear                1459 mm

   Ground clearance (at kerb weight)   110 mm

   Approach angle   12.40 deg

   Departure angle   280 deg

 Unladen weight         - total      701 kg            >inc. full

                                - front      278  kg             >fuel tank

                                - rear        423 kg              >

Unladen Dry Weight - total       658 kg

Maximum weight - total            928 kg                    incl.

                                - front      387 kg                     occupants

                                - rear       541 kg                    & luggage

Trailer towing   Not permissible

   Capacities

   Engine oil (refill inc. filter)                  4.5 litre (7.9 imp. pt)

   High/low dipstick mark difference     1.0 litre (1.8 imp. pt)

   Transmission oil                              2.1 litre (3.7 imp. pt)

   Fuel tank                                        36.4 litre (8.0 imp.gall)

   Cooling system                               8.0 litre (1.8 imp.gall)

   Front Suspension

                                                               Type          Independent. Upper and lower wishbone; co-axial     coil spring/telescopic damper unit; anti-roll bar

Ride height (for geometry check)     - front     1 00 mm below front end of chassis sider

                                                         - rear   1 1 0 mm below rear end of chassis sider

Steering axis Inclination   12' nominal

   Castor                    + 3.80; ± 0.20

                                   max. side/side 0.2'

Road use (Yokohama A036-R  or Pirelli P Zero tyres):

   Camber                  - 0.50; + 0. 1 0, - 0.20

                                   max. side/side 0.2'

   Alignment             0.2 mm toe-out overall; + 0.2 mm, - 0

Dry track use (Yokohama A038-R tyres)..

   Camber                  - 1.80; + 0.1', - 0.20

                                   max. side/side 0.20

   Alignment             0.5 mm toe-out overall; + 0.2 mm, - 0

   Rear Suspension

   Type                                                           independent. upper and lower wishbone

coil spring/telescopic damper. Toe control link.

   Ride height (for geometry check)   - front   1 00 mm below front end of chassis siderail

                                                        - rear   1 1 0 mm below rear end of chassis siderail

Road use (Yokohama A038-R  or Pirelli P Zero tyres):

   Camber                  - 2.00; + 0.20, - 0

                                   max.side/side 0.2'

   Alignment   1.5 mm toe-in each side; + 0.2 mm,-0

      max.side/side 0.2 mm

Dry track use (Yokohama A038-R tyres):

Camber   - 2.7'; ± 0.20

      max.side/side 0.2'

Alignment   2.5 mm toe-in each side; + 0.2 mm,-0

                                max.side/side 0.2 mm