Contents

Technical data

• General
• Cylinder block
• Cylinder head
• Valves & springs
• Camshafts
• Pistons
• Connecting rods
• Crankshaft
• Oil pump
• Dimensions
• Capacities
• Wheels & tyres
• Front suspension
• Rear suspension
• Electrical
• Transmission
• Clutch
• Brakes
• Steering
• Fuel consumption
• Coolant thermostat

Chassis

• General description
• Chassis straightness check
• Rear subframe

Bodycare & repair

• General description
• Lotus composite body features
• Bodycare
• Accident damage assessment
• Body panel bonding materials
• Replacement of bonded-on panels - general
• Front crash structure
• Windscreen frame
• Sill panels
• Rear bulkhead

Body fittings

• Removable roof
• Rear window shroud
• Front body access panels
• Engine cover lid
• Door hinge cover panel
• Front clamshell
• Rear clamshell
• Door mirrors
• Door shell brackets
• Door beam & hinge
• Door shell assembly
• Door glass, guide rails & winder mechanism
• Electric windows
• Door seals
• Door latch mechanism
• Central door locking
• Instrument binnacle & dash panel
• Windscreen 

Front suspension

• General description
• Geometry & adjustments
• Anti-roll bar
• Suspension disassembly/assembly
• Front wheel bearings
• For super sport suspension

Rear suspension

• General description
• Geometry & adjustments
• Suspension disassembly/assembly
• Rear wheel bearings
• Track use chassis rear brace kit
• Super sports suspension package

Engine & engine management

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• toyota 1zr repair manual
• General description
• Engine removal/replacement
• Special tools
• Engine management component location
• Maintenance operations

Engine management

• Diagnostic trouble code list
• Diagnostic scanner tools emp
• Engine management component location
• Mechanical throttle setting procedure
• 2006 model year electronic throttle control
• Diagnostic trouble code supplement - 06 m.y.
• Diagnostic trouble code supplement - 2011 m.y.

Transmission

• Introduction
• Gearchange mechanism
• Lubrication
• Driveshafts
• Transmission replacement
• Transmission overhaul & special tools 
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• toyota ec60 repair manual

Wheels & tyres

• General description
• Wheels
• Tyres
• Winter tyres & snow chains
• Punctured tyre emergency inflator
• Tyre pressure monitoring system 

Steering

• General description
• Steering wheel
• Upper column assembly
• Intermediate column
• Front wheel alignment & rack gaiters
• Rack & pinion assembly removal/replacement
• Adjustment of rack bar thrust pad 

Brakes system 

• General description
• Tell tale lamps
• Brake fluid check & change
• Front brake pad replacement
• Rear brake pad replacement
• Parking brake adjustment
• Brake discs
• Brake callipers
• 08 m.y. upgrade option
• Brake master cylinder
• Vacuum servo
• Pedal box
• Abs theory of operation
• Abs electro-hydraulic unit
• Wheel speed sensors
• Data link connector
• Special tools
• Lotus scanner tool checking procedures

Engine cooling

• General description
• Maintenance
• Drain/refill procedure
• Radiator & cooling fan
• Radiator fan control
• Radiator feed & return pipes
• Water pump & thermostat
• Oil coolers

Fuel system

• General description
• Fuel filling
• Precautions
• Fuel tank
• Fuel pump/sender assembly
• Charcoal canister

Electrics

• Cobra vehicle security alarm (prior '08 m.y.)
• Central door locking
• Electric windows
• Switches & instruments - driver's information
• Component location & fuse ratings
• Audio equipment
• Battery, battery cables & earthing points
• Wiper mechanism
• Harness routing
• Front lamp assemblies
• Contents list circuit diagrams
• Circuit diagrams
• Fuse layout
• Colour codes & abbreviations

Maintenance & lubrication

• Recommended lubricants
• Maintenance schedule
• Pre-delivery inspection
• Body paint inspection
• Licence plate fitment

Air conditioning, heating & ventilation

• General description
• Controls operation & airflow distribution
• Cooling fans & re-circulation pump
• Refrigerant handling
• Refrigerant pipework precautions
• Refrigerant oil
• Compressor
• Condenser
• Receiver-drier
• Expansion valve
• Heater/evaporator/fan unit
• Air distribution unit
• Refrigerant pipes
• Air blender & re-circ. flap actuators

Clutch

• General description
• Clutch pedal
• Hydraulic release system
• Clutch assembly

Airbag system

• General description
• Airbag tell tale
• Data link connector
• Trouble codes
• Diagnostic scanner tools
• Safety precautions, shipping, storage & disposal
• Theory of operation
• Sensor & diagnostic module (sdm)
• Driver airbag module
• Rotary connector
• Passenger airbag module
• Seat belt pre-tensioners

Supplement

• Concept & overview 
• Technical data 
• Body 
• Front suspension
• Rear suspension
• Engine
• Wheels & tyres
• Brakes
• Cooling
• Maintenance & lubrication
• Clutch
• Miscellaneous 
• Chassis
• Fuel system
• Electrical
• Circuit diagrams index