e tool kit r exchange tool kit

---

1.7 1.9

CARS Model:

All Elise/Exige & 2-Eleven Models fitted with Öhlins Dampers

Number: 2012/05

1.8

Date: 26.04.2012

Copy files should be maintained by: Service Manager

Service Reception

Supervisor

Parts Manager

TITLE: Renewal of updated stop washer to Öhlins 2 way adjustable damper assembly.

Remote reservoir hose

Road spring lock nuts

It has been noted that under extreme climatic conditions, the stop washer may show signs of corrosion and fatigue.

1.3

Under extreme conditions an excessively corroded stop washer could break around its circumference at its contact area on the damper base, allowing the outer area of the stop washer, slotted collar and spring to move downwards and rest against the plastic rebound adjuster ring.

Road spring

1.1

With the spring under compression, the collar is forced against the stop washer, retaining the lower end of the spring and washer in their correct positions within the damper assembly.

Damper Cylinder head

Measure

A ‘stepped’ collar with a slotted section manufactured within its radius is slid over the piston shaft and positioned between the upper face of the stop washer and the base of the road spring.

1.5

REASON: The lower end of the vehicle road spring fitted to an Öhlins adjustable damper is retained in position by the use of an integral stop washer which is fitted inbetween the end of the dampers piston shaft and rebound adjuster/suspension mount.

Slotted collar

HANGE TOOL KIT

Please note: In the event of this type of failure, the vehicle will still remain stable whilst driving as there is insufficient travel within the suspension assembly to allow the vehicle road wheel to foul either the wheelarch liner, body panels or any other suspension components. To rectify this issue, Öhlins have produced a modified stop washer, increasing its overall external dimensions making it more robust therefore improving its resistance to corrosion and fatigue. The revised stop washers are now fitted as a production running change.

Stop washer

Rebound adjuster

ER EXCHANGE TOOL KIT Comparison of original and modified stop washer

1.3

24500-01

Original Previous version stop washer Stop washer 03117-01

A120C6004S Updated version modified stop03117-06 washer Stop washer

NDEVRUEHUVKDOO

KHQH[WSDJH

When Stop washer has been replaced; Place Marker XXXXX-XX on the Banjo bolt. Both front and rear shock absorber.

L KIT

washer 03117-06. er may be or death.

Continued.....

Bulletin number 2012/05 continued Page 2

CARS

This action was also carried out on service replacement units despatched from the Lotus Aftersales warehouse as listed below. Öhlins Spring/damper units affected Part numbers A128C4001F A128C4002F A128D4001F A128D4002F

Description LHF spring/damper assembly RHF spring/damper assembly LHR spring/damper assembly RHR spring/damper assembly

Production Applications Lotus Exige 240 260 & Elise SC

Part numbers B & C127C4001F B & C127C4002F B & C127D6000F B & C127D6001F

Description LHF spring/damper assembly RHF spring/damper assembly LHR spring/damper assembly RHR spring/damper assembly

Production Application Lotus 2-Eleven

Part numbers CLS3C6001J CLS3C6002J BLS3D6005J BLS3D6006J

Description LHF spring/damper assembly RHF spring/damper assembly LHR spring/damper assembly RHR spring/damper assembly

Motorsport & Aftersales Applications Toyota powertrain Lotus Elise and Exige

Part numbers ALS3C0114F ALS3C0115F ALS3D0117F ALS3D0118F

Description LHF spring/damper assembly RHF spring/damper assembly LHR spring/damper assembly RHR spring/damper assembly

Motorsport Application Lotus 2-Eleven GT4

In conjunction with Ohlins, a stop washer exchange tool kit has been produced and is used to fit the modified stop washers. A quantity of modified stop washers and a single tool kit will be mandatorily issued to all Lotus Dealerships and Authorised Repairers in markets where sales of potentially affected vehicles have been recorded by Lotus Cars Aftersales Department. Part Number Description Kit Contents Qty T000T1531F Stop washer exchange kit ‘C’ spanners 2 Soft vice jaws 2 Loctite 278 1 bottle Part Number Description A120C6004S Stop washer 4/car ACTION: Parts Department Please check all stock you may have of any affected part numbers displayed in this bulletin. Any modified spring/damper assemblies can be easily identified by the fitment of the thicker stop washer as well as an adhesive label (a green dot) which has been affixed to either the remote reservoir or the reservoir hose bolt where it is affixed to the dampers cylinder head. Continued............

CARS

Bulletin number 2012/05 continued Page 3

Any assemblies that have been modified can remain in dealer stock and sold as normal. Any assemblies that have not been modified should be returned for a parts credit using the credit request procedure as shown in the Lotus Aftersales Parts Policy and Procedures Manual. Please check your parts sales records to determine if you have sold any of the affected part numbers (either as counter sales or to your Service Department). Where records exist, please liaise with your Service Department and contact any customers who have had affected assemblies fitted and make arrangements to inspect their vehicles at a mutually convenient time. Service Department Action Where records indicate that a vehicle was fitted with Öhlins spring/damper assemblies at the time of production will be shown as outstanding campaign number 2012/05 on Lotus Dealer Connect when its VIN is entered on option DC611. If a vehicle affected by campaign number 2012/05 enters the workshop carry out the procedure listed below. If a vehicle enters the workshop and is fitted with affected Öhlins dampers but its VIN is not listed as outstanding campaign number 2012/05, then please contact the Lotus Warranty Department with the full VIN and owner details as well as any additional information as to when and where the dampers were purchased. Procedure 1 Inspection of front damper assemblies • Turn the steering wheel to a full LH & RH lock • The front damper/spring assemblies will be accessible for inspection on the outward turned lock, inspect both the stop washer and remote reservoir attached to the lower wishbone crossbrace (or front crash structure on the 2-Eleven). • If a modified washer has been fitted and the green sticker has been affixed – carry out no further remedial action. (See illustrations ‘B’ on page 4). Inspection of rear damper assemblies • From rearwards of the road wheel and the side of the diffuser panel, inspect the LHR/RHR lower dampers and remote reservoirs attached to the toe link rod (or rear subframe as viewed from above on the 2-Eleven). • If a modified washer has been fitted and the green sticker has been affixed – carry out no further remedial action. (See illustrations ‘B’ on page 4). If the vehicle has been fitted with modified Öhlins damper assemblies then a warranty claim for inspection only can be submitted on Lotus Dealer Connect (see charges section of bulletin for details). If the modified washers have not been fitted as per the example ‘A’ illustrations on page 4, make a note of the vehicles front and rear ride height and carry out procedure 2 as shown on page 5.

Continued............

Bulletin number 2012/05 continued Page 4

CARS

Öhlins damper IDENTIFICATION in situ



Öhlins front damper in situ

A

Thin stop washer

Öhlins rear damper in situ

A

Thin stop washer

No marking on reservoir No marking on reservoir

B

Thicker stop washer

B Green marking on reservoir

Green marking on reservoir

Thicker stop washer

Continued............

TIK L

Bulletin number 2012/05continued Page 5

CARS

STOP WASHER EXCHANGE TOOL KIT Procedure 2 Damper base

Part 1: Stop washer removal

1 Remove Stop 03117-01 Once Washer the vehicles front and rear ride height has been noted, re1.1 (Disassemble) move the damper/reservoir assembly from the vehicle (refer to sec-

3.1 1.3

tions DH.3 and CI.3 of the Elise Service Notes). 1.1 Measure the distance between cylinder head and lock nut. See Measure 1. Using the two ‘C’ spanners supplied in the stop washer kit, re¿JXUH1RWHWKHPHDVXUH move the spring from the damper assembly (also refer to sections 1.2 DH.3 and CI.3 of the Elise Service Notes).

Rebound adjuster

setting by turning the rebound adjuster’s knurled plastic ring located on the base of the damper clockwise and note the number of clicks. &RXQWUHERXQGFOLFNVE\WXUQLQJFORFNZLVH1RWHQXPEHURIFOLFNV

Piston shaft

/RRVHQWKH/RFNQXW5HPRYHWKH6SULQJIURPWKH6SULQJFOLS 5HPRYHWKH6SULQJ 2. Note the dampers current rebound

1.3 1.4

Stop washer

1.5 Note: It is important to carry out the above procedure for resseting the damper upon 2/2 re-assembly.

Step 4

2SHQWKH5HERXQGDGMXVWHUWXUQFRXQWHUFORFNZLVH DSSUR[WXUQV

1.5

Issued 2011-09-20

5HPRYHWKH6SDFHUVLQWKH(QGH\HLIDQ\8VHWZRVFUHZGULYHUV

3. Open the rebound adjuster (turn the knurled plastic ring counter clockwise) approximately 4 Push the Bump rubber all the way down towards the Cylinder head. LQGLFDWHGDUHDVHHSDJH  complete turns. 1.6

After 1.7 replacing the Stop washer, mark the shock absorber in the

Spacers

2.8 3XWWKHVKRFNDEVRUEHULQDYLFHZLWKVRIWMDZV  4. Using two suitable screwdrivers or appropriate

workshop bars, remove 5HPRYHWKHVKRFNDEVRUEHUIURPWKHYLFH 1.8

the spacers located in

the base of the damper. 2.7 8VHDKHDWJXQDQGKHDWWKH(QGH\HDWWKHVKDIW

Mount 1.9 the spring. Set to noted measure in step 1.1 Disassemble.

Vice clamps as supplied in T000T1531F Step 7

1.7

5. Push the bump stop rubber all the way down the piston shaft towards the cylinder head.

2.6 5HPRYHWKH(QGH\HIURPWKH6KDIW8VHDQDGMXVWDEOHZUHQFKDQG turn counter clockwise. step 1.3 Disassemble. Adjust rebound. Set to the number of clicksassembly noted in 6. Place the damper 1.10

in a vice, clamping

2.5 it around the piston shaft using the soft jaws 5HPRYHWKH6WRSZDVKHULIVWLOORQWKH(QGH\H 7DSJHQWO\ZLWKD plastic hammer. in the Mount the Spacers insupplied the End eye.

1.8

stop washer kit.

2.4

1.10

Step 6

7. Using a heat gun, apply gentle heat to the base 2 Stop Washer 03117-06  Mount 7LJKWHQLQJWRUTXH1P of the damper where it is attached to the piston Mount the End eye and Stop washer. (Assemble) shaft and stop washer.

2.1

0RXQWWKHQHZ6WRSZDVKHU RQWKH(QGH\H7DSJHQWO\ 8VH/RFWLWH 8. Using an adjustable wrench, turn the base of Clean threads onthe the shaft. damper counter clockwise unscrewing it with a the plastic hammer.

1.9

2.3 2.1 2.2 2.2

with a the plastic hammer. Clean threads on the shaft. 9. Remove the stop washer (if still attached 0RXQWWKHQHZ6WRSZDVKHU RQWKH(QGH\H7DSJHQWO\ 8VH/RFWLWH

2.1 2.3

8.1

from the dampers piston shaft.

to the damper base) by tapping gently with a plastic hammer.

(Assemble) Mount the End eye and Stop washer. 2 Mount 7LJKWHQLQJWRUTXH1P Stop Washer 03117-06 2.4

1.10

1.9 8 Step

2.1

Continued............

Mount Spacers in the End eye. plastic the hammer. 5HPRYHWKH6WRSZDVKHULIVWLOORQWKH(QGH\H 7DSJHQWO\ZLWKD 2.5

1.10 Adjust rebound. Set to the number of clicks noted in

step 1.3 Disassemble. turn counter clockwise. 5HPRYHWKH(QGH\HIURPWKH6KDIW8VHDQDGMXVWDEOHZUHQFKDQG 2.6

1.9 Mount the spring. Set to noted measure in step 1.1 Disassemble. 8VHDKHDWJXQDQGKHDWWKH(QGH\HDWWKHVKDIW 2.7

1.8 1.7

9.1

2 Mount Stop Washer 03117-06 (Assemble) 2.1

1.9

0RXQWWKHQHZ6WRSZDVKHU RQWKH(QGH\H7DSJHQWO\ with a plastic hammer.

2.2

Bulletin number 2012/05 continued Page 6

CARS

Clean the threads on the shaft.  8VH/RFWLWH

OP WASHER EXCHANGE TOOL KI 2.3

Mount the End eye and Stop washer.  7LJKWHQLQJWRUTXH1P

1.10

2.4 Part 2: Stop washer fitment

2.1 10 Step

Step 9

10. Tool Position the new24500-01 stop washer (A128C6004S) onto the Exchange Kit 2.5

0-01 7-05

?

Mount the Spacers in the End eye.

damper base and tap gently with a plastic hammer to

Adjust rebound. Set ittois theproperly number ofmounted. clicks noted in 2 ensure step 1.3 Disassemble.

2 1 ply a light of Loctite 278 the cleaned threads. Mount the spring. Set tocoating noted measure in step 1.1to Disassemble. ? 2.7

2.6 11. Clean the threads on the dampers piston shaft and then ap-

Fit new stop 12. Mount the damper base and stop washer to the damper Remove washer 5HPRYHWKHVKRFNDEVRUEHUIURPWKHYLFH piston shaft, using a crows foot spanner, torque the base original A120C6004S 2.8 Previous version to 60Nm. stop After replacing the Stop washer, mark the shock absorber in the washer replaced with Stop washer 03117-06. Stop washer 03117-01 LQGLFDWHGDUHDVHHSDJH  13. Refit the spacers in the damper base.

must be t replaced the Shock absorber may be Removeinjury the damper from the vice. ch can cause 14. personal or death.

tions DH.3 and CI.3 of the Elise Service Notes).

HUDFFRUGLQJWRWKHVWHSVRQWKHQH[WSDJH

LOTUS;

17. Using a green coloured indelible marker pen/paint stick, mark the head of the reservoir hose to damper bolt with a green dot.

Stop washer

Issued 2011-09-20

15. Reset the rebound adjuster to its original setting2/2 to the number of clicks noted in step 2. KDVEHHQUHSODFHGWKHVKRFNDEVRUEHUVKDOO

Marker provided in this kit. 16. Refit the spring to the damper assembly (refer to sec-

Updated v

Once stop washer When Stop washer has been has been replaced Placebanjo Marker mark boltXXXXX-XX on with green paint. Banjo bolt. Both front and re

absorber.

18. Mark the casing of the remote reservoir near its connection to the reservoir hose with a green dot (ensuring that the mark is placed in a position that will be visible with the reservoir in situ on the vehicle as per ‘B’ illustrations on page 4). Refit the damper assembly back onto the vehicleExige (refer to 260 sections DH.3 and CI.3 of the Elise Service Notes).

M Lotus Elise K-serie

left/right front/rear

/29-

2(0/RWXV([LJH

OHIWULJK

0/RWXV(OLVH5& CHARGES:

OHIWULJKWIURQWUHDU

LOF 1-4F61

OEM Lotus 2-Eleven

left/righ

Repeat procedure 2 to all of the vehicles dampers and once complete, ensure the vehicles ride height is the same as noted before damper renewal, road 2-Eleven test and ensure your vehicle has maintained stability. Procedure 1 carried out: Vehicle dampers already fitted with modified stop washers. A warranty claim for 0.1 hours labour per vehicle2-Eleven can be submitted on Lotus Connect, option DC603, Sport Bulk Entry Campaign number 2012/05, Select inspection type 1.

0/RWXV(OLVH([LJH5 OHIWULJKWIURQW Lof 1-4F62 OEM Lotus 2-Eleven Sport Procedure 2 carried out: Vehicle dampers require fitment of modified stop washers. 0/RWXV(OLVH([LJH OHIWULJKWUHDU

autions

left/righ

A warranty claim for 4 hours labour and 4 x A120C6004S stop washers per vehicle can be submitted on Lotus Connect, option DC603, Bulk Entry Campaign number 2012/05, Select inspection type 2.

Note: As it is not necessary to disturb any of the suspensions wishbone fixings to carry out this procedure, claims for carrying out steering and geometry checks or adjustments relating to this bulletin will not be authorised. In this manual, mounting instructions and Ends.

ber/front fork/steering damper is an important e and will affect the stability.

Safety Symbols

other tech documents, important information concerning safety distinguished by the following symbols:

The Safety Alert Symbol means: Warning! Your safet