Lotus - Exige - Workshop Manual - (2006)2

MWR Lift Point Kit – Lotus Elise/Exige/2-Eleven Disclaimer: if you are not comfortable working on your car, hire a qualified technician to perform this installation. Failure to follow these instructions could result in damage to your car or personal injury. 1. Remove the engine undertray: remove all the small bolts from the sides and rear of the tray, then the two larger hex (Allen) button head screws. 2. Raise the car off the ground using the factory lifting points in the diagram below. If using a floor jack, jack up each side of the car using jacking points A and place jack stands under the lift points B and either C or D (using D will require removing the rear diffuser). If using a 4-point lift you must remove the rear diffuser and use points B and D. DO NOT USE POINT A WITH A 4-POINT LIFTthis can cause the vehicle to be unstable and fall off the lift. 3. Carefully examine the extruded aluminum frame openings on both sides of the car just forward of the lower rear A-arms for any burrs or sharp edges using a gloved hand. This is the place the frame plates from the kit will be installed. The end of the frame is cut off to clear the forward edge of the A-arm and there can be many sharp edges. Also check the hole in the frame (where the mounting bolt for the frame plates will go) for burrs on the inside and remove any sharp edges or burrs that could cut you or interfere with the sandwich plates fitting flat against the frame surfaces. 4. Insert the upper frame plates into the frame openings making sure to use the plate with the cut out on the left hand (driver's) side and with the angle end following the cut of the frame. [See photos C,D,E, F & G] 5. Drop in one of the 1 1/2" flange head bolts through the upper frame plate and frame hole so the threads are visible from under the frame. [See photos O & P] 6. Assemble the flat head hex cap (Allen) screws using a 5/16" Allen wrench on the screw and a 3/4" wrench on the nut into the countersunk holes in the lower plates using the thin lock nuts to tighten them into place. [See photos I, J, K & L] 7. It is easier to install the lift kit extension pins with the lower frame plate off the car, so screw the pins onto the lower plates now and tighten them in place with a strap wrench using a bench vise to hold the plates (or other tools suitable for the job). USE LOCTITE RED HIGH STRENGTH THREADLOCKER ON THE SCREW THREADS BEFORE INSTALLING THE EXTENSION PIN. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY, OR DAMAGE TO THE VEHICLE. [See photos M & N] 8. Check the area of the frame where the rocker panel lip is glued to it by holding the lower plate in place to see if it fits flush to the edges of the frame and rocker panel. Trim off any excess adhesive that causes misalignment of the plate with the frame as necessary with a razor blade or knife. [See photo Z2] 9. Assemble the lower plate to the underside of the frame by holding the plate up to frame so the loose bolt passes through the hole in the lower plate and the notch in the plate fits around the inner rocker panel lip. The lower plate for the left side has a relief machined into the face to clear the clutch hose bracket so slip it between the clutch hose tube and the bracket. You may have to tweak the tube slightly if it is tight to the lower plate. Be gentle and only move it enough to give clearance between it and the lower plate. [See photos Q, R, S & T for left side assembly, and photos U, V, W & X for right side assembly.] 10. Thread the flanged locknut onto the bolt and use two 3/4" wrenches or one wrench and a 3/4" socket/extension/ratchet wrench combination to tighten everything into place. An air ratchet or impact wrench would make this even easier. W hile tightening the bolt, make sure to keep the plates aligned with the frame cut off and the rocker panel lip. [See photos Y & Z2] 11. Lower the car to the floor and carefully position your lift arms under the B lift points and the new lift pins. Start lifting the car slowly and inspect the lift points at the frame for any misalignment, bending or flexing. If anything does not look right, lower the car immediately and correct the problem. 12. Once you are sure everything is correct, lift the car to a normal overhead height and do a thorough walk around to establish that the lift points are secure. [See photo Z3] 13. Once you are satisfied with the inspection, pick up your under tray and slip it into position under the engine compartment. Install all the small bolts around the edges and tighten them in place and lastly tighten up to two center screws. 14. Lower the car. From now on it is simply a matter of placing the lift arms under the pins and forward lift points and raising the car. DO NOT USE A JACK ON THE LIFT POINT PINS. DOING SO COULD CAUSE FRAME DISTORTION OR COULD DAMAGE THE LIFT POINT ASSEMBLY. USE LOCTITE RED HIGH STRENGTH THREADLOCKER HERE M l--=_j