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2004 Lotus Elise & Exige Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Lotus Model: Elise & Exige Year: 2004 Codes Chassis Code Elise: Series 2 (S2) Chassis Code Exige: Series 2 (S2) 👋 Introduction Market Position Positioning:...
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2004 Lotus Elise & Exige Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Lotus
Model:
Elise & Exige
Year:
2004
Codes
Chassis Code Elise:
Series 2 (S2)
Chassis Code Exige:
Series 2 (S2)
👋 Introduction
Market Position
Positioning:
Lightweight, high-performance sports cars
Competitive Analysis
Competitors 2004:
Porsche Boxster, Honda S2000, BMW Z4, Audi TT Roadster
Key Features Vehicle
Handling Philosophy:
Renowned for exceptional handling, braking, and steering feedback (Lotus 'car as a driver' philosophy)
Chassis Construction:
Lightweight bonded aluminum extruded chassis
Key Features Manual
Usefulness For Users:
Essential resource for owners undertaking maintenance and repairs, as used by official service centers
Value Proposition:
Provides detailed, factory-authorized procedures, saving on labor costs and ensuring correct repairs
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and maintenance for 2004 Lotus Elise and Exige models
Engine Variants Covered:
1ZZ and 2ZZ engines
Specialized Supplements:
Includes supplements for Exige Supercharged and 2-Eleven variants
Page Count
Estimated Page Count:
Extensive (exact count not specified, but described as 'complete')
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Delivery Method:
Digital Delivery (Instant Download)
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed coverage of engine control systems and diagnostics
Engine Mechanical:
Comprehensive engine component repair, overhaul, and specifications
Chassis And Suspension:
Front and rear suspension systems, steering, and alignment procedures
Body And Trim:
Body care, repair, and fittings, including interior and exterior components
Brakes:
Brake system components, hydraulic circuits, and troubleshooting
Cooling System:
Engine cooling system diagnostics, maintenance, and repair
Fuel System:
Fuel delivery, injection, and evaporative emission control systems
Electrical System:
Wiring diagrams, component testing, and electrical system diagnostics
HVAC System:
Air conditioning, heating, and ventilation system service
Clutch System:
Clutch assembly, hydraulic system, and operational adjustments
Passive Restraints:
Airbag system information and related components
Transmission:
Manual transmission service and repair
Wheels And Tires:
Wheel and tire specifications and maintenance
Procedures Included
Maintenance And Lubrication:
Scheduled maintenance, fluid checks, and lubrication points
Troubleshooting:
Diagnostic procedures for common issues and system faults
Repair And Overhaul:
Detailed step-by-step repair instructions for all major components
Specifications And Data:
Comprehensive technical data for engine and vehicle systems
Technical Depth
Depth:
Extremely high, suitable for professional mechanics and experienced enthusiasts
📊 Manual Specifications
File Format
Format:
PDF
Reader Requirement:
Requires any PDF reader software
Print Quality
Quality:
High (implied by factory service manual standards)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine Elise
Engine Code:
1ZZ-FE (standard)
Configuration:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
1794 cc (1.8 Liters)
Bore X Stroke:
82.0 mm x 85.0 mm
Compression Ratio:
10.0:1
Horsepower Elise 111S:
156 hp @ 6400 rpm (variable valve timing)
Torque Elise 111S:
126 lb-ft (171 Nm) @ 4200 rpm
Fuel System Elise:
Electronic Fuel Injection (EFI)
Primary Engine Exige
Engine Code:
2ZZ-GE (Supercharged)
Configuration:
Inline 4-cylinder, DOHC, 16-valve, VVTL-i (Variable Valve Timing and Lift - intelligent)
Displacement:
1796 cc (1.8 Liters)
Bore X Stroke:
82.0 mm x 85.0 mm
Compression Ratio:
11.5:1
Horsepower Exige:
189 hp @ 7800 rpm (supercharged)
Torque Exige:
155 lb-ft (210 Nm) @ 6000 rpm
Supercharger:
M-62 Supercharger with intercooler
Fuel System Exige:
Electronic Fuel Injection (EFI)
🔧 Transmission
Standard
Type Elise:
Toyota C60 6-speed Manual
Type Exige:
Toyota E153 6-speed Manual (potentially reinforced for supercharged application)
Features
Gear Ratios Elise C60:
Refer to manual for specific ratios
Fluid Type:
Refer to manual for specific fluid specification (e.g., API GL-4/GL-5 synthetic)
📐 Dimensions
Exterior
Length:
Approx. 3795 mm (149.4 in) for Elise, 3795 mm (149.4 in) for Exige
Width:
Approx. 1719 mm (67.7 in)
Height:
Approx. 1130 mm (44.5 in)
Weights
Curb Weight Elise:
Approx. 750 kg (1653 lbs)
Curb Weight Exige:
Approx. 830 kg (1830 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Low production volume, specialized sports car category generally exempt from standard consumer ratings)
Active Features
Braking System:
Four-wheel AP Racing disc brakes (vented front, solid rear typically)
ABS:
Available on some models/markets, refer to specific vehicle configuration
Passive Features
Airbags:
Driver and passenger airbags (as per manual's 'passive restraint' section)
Roll Hoop Cage:
Integral roll-over protection structure within the chassis
💡 Technology Features
Infotainment
Audio System:
Basic radio/CD player typically found in this era of lightweight sports cars. Refer to manual for specific integration details.
Driver Assistance
Systems:
Limited driver assistance systems, prioritizing driver engagement. ABS availability varies.
Connectivity
Features:
No integrated Bluetooth or advanced connectivity typically found in modern vehicles.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time interval (typically 6,000-10,000 miles or 1 year)
Major Service Interval:
Refer to manual for timing belt (if applicable, check engine variant), spark plugs, and other major component checks.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity (e.g., 5W-30, 10W-40) and API/ACEA specifications (e.g., API SN or equivalent)
Coolant Type:
Ethylene glycol-based, long-life coolant (specific mix ratio and type to be confirmed in manual)
Brake Fluid Type:
DOT 4 (high-performance brake fluid recommended)
Known Issues
Typical Elise Exige S2 Points:
While the manual covers all procedures, common owner observations might include clutch wear, minor electrical gremlins, and potential for suspension component wear due to hard driving. Supercharger belt tension and intercooler integrity for Exige are critical.
📚 Vehicle History
Brand Heritage
Philosophy:
Founded by Colin Chapman, emphasizing 'lightweight and simplicity'
Model Evolution
Elise Genesis:
Launched in 1996 as a spiritual successor to the Lotus Elan, focusing on pure driving experience
Exige Genesis:
Introduced as a more track-focused, hard-top variant of the Elise
S2 Introduction:
Series 2 launched in 2001 with significant updates, including the adoption of Toyota engines
Production
Manufacturing Location:
Hethel, Norfolk, United Kingdom
Engine Supplier:
Toyota Motor Corporation
🏆 Awards & Recognition
Recognitions
General Acclaim:
Lotus Elise and Exige models are consistently lauded for their driving dynamics, handling prowess, and purist sports car experience by automotive journalists and enthusiasts.
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