Lotus - Evora S - Workshop Manual - (2012)

CARS Date: 10.12.2012 Model: Evora S & S-IPS Prior to ‘12MY VIN CH_10156 Number: 2012/03R USA Copy files should be maintained by: Service Manager Service Reception Supervisor Parts Manager TITLE: Retrofitment of revised RH cylinder bank Variable Valve Timing (VVT) pipe. REASON: To reduce the potential for oil leaks from the VVT pipe. Background To prevent the revised auxiliary drive belt fouling on any ancillary engine components, the Variable Valve Timing (VVT) oil feed pipe located on the engines RH cylinder bank was modified to change its positioning as from the introduction of the Evora S, The pipe modification consisted of a small section of rubber hose joining the modified VVT upper and lower pipe union connections together using two 16mm hose or spring clamps. Originally positioned forward of the cylinder head, the modified 3 piece pipe for the supercharged engine is now routed over the top of the RH camshaft cover, travelling downwards in front of the timing chain cover before terminating at its cylinder head connection located behind the Power Assisted Steering (PAS) pump. Upper VVT connection Hose & spring clamps Lower VVT connection Auxillary drive belt PAS pump MODIFIED VVT PIPE FITTED ON ’S’ MODELS FROM START OF PRODUCTION e252 It has been determined that under extreme circumstances the rubber hose section of the VVT pipe can leak. Risk A failure of the VVT oil feed pipe may result in oil being deposited onto the engine as well as the exhaust system. This could cause potential engine failure and a potential risk of fire because of the presence of flammable vapour which could result in a crash. ACTION: The 3 piece VVT pipe fitted to vehicles prior to ‘12MY VIN BH_10156 should be replaced with the current production single piece metal VVT pipe and retaining clip. Continued..... Bulletin number 2012/03R USA continued page 2 CARS • Affected vehicle owners have now been informed that a precautionary safety recall applies, and advising them to contact their dealer to have the necessary rectification work carried out. A specimen letter is attached for information. • Please check and identify any affected VIN (Vehicle Identification Numbers) against your dealer inventory or dealer demonstrators VIN number records. • There are 98 vehicles applicable to this recall action; any affected vehicle by campaign status will be displayed if its VIN is entered onto DC611 on the Lotus Dealer Connect warranty system. • IMPORTANT Dealers should immediately check any cars in their sales stock or demonstrator fleet, or any affected customer cars currently on site. Federal law requires that any vehicles in dealer inventory are rectified before retail delivery. • A quantity of current production level VVT pipes and unions will be mandatorily issued to all Lotus Dealerships. • Additional quantities of pipes and washers can be ordered via the parts system of Lotus Dealer Connect as required. Parts Required Description Part Number VVT oil pipe fitting kit* A132E0138J Qty/car 1 *Kit Contents Description VVT oil feed pipe Gasket, union bolt, oil pipe, upper Gasket, union bolt, oil pipe, lower Oil pipe ‘P’ clip Oil pipe clip spacer M6 x 30 hex flange bolt Qty/kit 1 2 1 1 1 1 Note Individual part numbers for kit are listed in section 40.05 of the Service Parts List. Method of Repair Removal Procedure: 1. Raise the vehicle and remove the rear undertray – see service notes introduction section for further information. 2. Remove the RHR wheel and wheelarch liner - see service notes section BV.17 for further information. 3. Release the tension from the auxiliary drive belt and remove it from the PAS (Power Steering Pump) pulley – see service notes engine section EJ.4 for further information. 4. Release and remove the upper and lower mounting bolts securing the PAS pump to the engine block - see service notes section HI.11 for further information on bolt removal. Continued..... Bulletin number 2012/03R USA continued page 3 CARS 5. Lower the PAS pump to gain access to the VVT pipes lower banjo bolt union, Take care not to place any strain on either the reservoir or steering rack hoses that are still attached to the pump - see service notes section EJ.14 for further information. 6. Place a cloth on top of the PAS pump and position a suitable container below the vehicle to catch any oil which may spill out during the removal of the lower banjo bolt. 7. Using a 17mm socket and ½ breaker bar, release the lower banjo bolt and withdraw it from the pipe and engine assembly, (the union gasket will probably remain attached to the lower pipe assembly). 8. From the RHR wheel arch area release the upper hose clip securing the subframe heat duct pipe to the clamshell exit vent. Pull the top section of the pipe to one side to gain access to the rearmost PAS reservoir bracket to back stay fixing bolt. See service notes section HI.12 for further information. 9. Release and remove the 3 M8 bolts and nuts (torque 10Nm) securing the PAS bracket to the backstay, taking care not to place any strain on the PAS hoses, position the PAS reservoir downwards slightly to gain access to the upper VVT pipe banjo bolt. 10.From the RHR wheelarch area, release the upper union banjo bolt and withdraw it from the engine, collect the union pipe gaskets and VVT oil filter/strainer which is also attached to the end of the bolt - see service notes section EJ.14 for further information. 11. Withdraw the pipe from the vehicle via the wheelarch area. Fitment of the latest steel pipe is the reversal of removal except: -- Open up the new oil pipe ‘P’ clip, part number A132E0134F and fit it around the middle of the new VVT oil feed pipe (A132E0102F) ensuring to fit it in the correct orientation so that the rear surface of the clip will be facing towards the cylinder head once the new VVT oil pipe is positioned into place. VVT oil filter/strainer Upper banjo union bolt & gaskets Oil pipe ‘P’ clip, spacer, fixing bolt & unused timing cover thread Lower banjo -- Re-using the existing upper banjo bolt, union bolt & fit it into place on the replacement pipes gasket (A132E0102F) upper union connection using 2 new (A132E6234S) sealing gaskets. -- Clean the gauze filter previously removed and refit to the end of the fitted banjo bolt. sb174 -- Position the assembled VVT pipe onto the engine, fitting the upper banjo bolt hand tight only at this stage. Continued..... Bulletin number 2012/03R USA continued page 4 CARS -- From underneath the vehicle, fit the new lower single piece sealing gasket (A132E6244S) around the end of the lower pipe union. Re-using the original lower banjo bolt, place it through the lower pipe union and gasket and hand tighten to the engine block. -- Ensure the pipe orientation is correct and tighten both union connectors to 45Nm. -- Apply a small amount of Permabond A130 around the thread of the M6 x 30 hex flange bolt (A124W5294F). -- From the wheelarch area, align the bolt hole of the ‘P’ clip over the unused M6 threaded hole located in the timing cover at the RH cylinder head bank area just above the rectangular steel inspection plate, closing the clip around the pipe as tightly as possible once the 2 holes are aligned. -- Position the oil pipe clip spacer (A132E0135F) between the ‘P’ clip and threaded hole in the timing cover. -- Fit the M6 x 30 hex flange bolt through the ‘P’ clip and spacer and into the timing cover threaded hole and torque to 10Nm. -- Refit the PAS reservoir assembly and subframe heat ducting pipe. -- Refit the PAS pump and auxiliary drive belt. Care point: Removing the PAS pump from the engine block may cause the union bolt securing the high pressure fluid pipe to the pump body to loosen which may potentially cause a power steering fluid leak. Once the PAS pump is refitted to the engine, it is essential to check the torque of the high pressure pipe union bolt (torque 30Nm). PAS reservoir VVT pipe in situ ‘P’ clip retaining pipe to timing cover PAS pipe removed for clarity sb175 To gain access to the union bolt to check the torque will require the removal of the engine access panel in the luggage compartment; see service notes section EJ.2 for further information. -- Top up vehicle engine oil (if required). -- Run the engine to normal operating temperature and check for oil leaks, refit the rear undertray assembly and RHR wheelarch liner. Timely Repair The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. Failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. Continued..... CARS Bulletin number 2012/03R USA continued page 5 If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonable equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Lotus Customer Service if their dealer does not remedy the condition within three (3) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration. CHARGES: A warranty claim for 2.5 hours labour and 1 fitting kit/car (VVT oil pipe, gaskets and retainers as listed) may be claimed by submitting a claim on Lotus Connect, option DC603, Bulk Entry Campaign, enter campaign number 2012/03R. Ends.    SAFETY RECALL NOTICE [lotus owner] [address line 1] [address line 2] [address line 3] Lotus Recall 2012/03R (NHTSA recall # 12V-477) Vehicle VIN «VIN17» Dear «GreetingLine» Lotus has identified you as the registered owner of the above vehicle. This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. REASON FOR THIS RECALL Lotus has decided that a defect, which relates to motor vehicle safety, exists in certain 2011 model year Evora S (Supercharged) vehicles. It has been determined that engine oil leaks have occurred from an oil pipe specifically used on the supercharged engine in a small number of USA specification vehicles manufactured between 17 December 2010 and 20 September 2011. WHAT IS THE RISK? A failure of this pipe may result in oil being deposited onto the engine as well as the exhaust system. This could cause potential engine failure and an increased risk of fire because of the presence of flammable vapour. This could result in a crash, serious injury or fatality. WHAT WE WILL DO The remedial work required involves the replacement of the engine oil pipe to the more durable current production specification pipe. Your Lotus dealer will carry out this work without charge to you. WHAT SHOULD YOU DO? Please contact your Lotus dealer as soon as possible to arrange a service date and to enable the dealer to order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer and the parts are available. The labor time necessary to perform this service correction is approximately 2.5 hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.    Your Lotus dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within three (3) days, we recommend you contact Lotus customer service by calling 1-80024-LOTUS (1-800-245-6887). If, after contacting your dealer and Lotus customer service, you are still unable to have the safety defect remedied without charge and within a reasonable time, you may wish to write to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. This letter identifies you as an owner of a vehicle affected by this recall. Presentation of this letter to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the cut-off slip below and returning it in the postage paid envelope enclosed. If you are a vehicle lessor, Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the vehicle lessee within ten days. Again, we are sorry to cause this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products. Mr. R Mann Customer Services & Warranty Manager Lotus Cars USA, Inc. - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Lotus Recall 2012/03R (NHTSA recall # 12V-477) Please note that the ownership of Lotus Evora, VIN «VIN17», has been transferred to: Name: Address: City: State: Zip: 