For this edition of Elise Tech Tips I would like to examine a few service issues that have been brought to my attention and pass along some winter storage tips that are specific to the Elise. All of the service issues are easy to correct and while two of them are irritants, the third could ruin your day.
The first issue which continues to surface with regularity is the inability to completely roll up a side window. This problem is usually not noticed until you need to raise a side window after having had it in the down position for an extended period of time.
If you find the window stops short of full height leaving a gap between the window and top seal when raised, the most likely cause is a backed out window channel fixing screw. 
To locate this screw, open the door with the window lowered and look between the rubber window seal strips at the top and rear of the door as shown in the photo. Look closely at the window channel located there for a Posi-drive screw head (looks like a Phillips head) and use the proper screw driver to tighten it. If the screw was loose you have found the problem. When the window rides up the channel and the screw is backed out, the head of the screw will foul the window glass and stop it short of full height.
You may also want to check the forward window channel attaching screw which can be accessed in the same manner as well as the channel screws in the other door. This simple repair can really make a big difference on a rainy day when your window has failed to completely roll up.
The next item I would like to bring up is a problem with the alarm system that is simple to correct. If upon attempting to arm the alarm all you hear is a buzzing noise and the alarm fails to set, first check the position of the interior lamp. For some reason the interior lamp circuitry is incorporated into the alarm system and if the lamp is not set to the “on” position the alarm will issue a failure to arm warning in the form of the buzzing sound. This buzzing is the same sound that comes from a tripped front panel, door or engine lid sensor. The interior lamp is in the correct position when the lens is facing downward and the light comes on with the door opened, but off when the door is closed.
If the alarm system still fails to arm after checking the interior lamp position, check the aforementioned sensors. It is not uncommon for one of the forward clam access panels to be replaced incorrectly which trips the alarm sensor. Make sure the doors are completely shut as well as the engine lid. If any of these parts are slightly ajar the sensors will be tripped and the alarm will not set. If all the panels appear properly closed, check the sensors them-selves for proper adjustment and function and correct their positioning as needed.
The next problem is relatively new and related to the oil cooling system at the oil filter sandwich plate. The stock Toyota engine has an oil filter plate with a integrated oil cooler that uses coolant from the engine’s water jacket to regulate the oil temperature. Lotus fitted either one or two remote standard oil coolers in the nose of the Elise and removed the Toyota oil cooler to be re-placed with an oil filter sandwich plate of their own design. The Lotus sandwich plate does not require the water jacket cooling so they fitted a “U” shaped tube to the coolant hoses to effectively bypass their sandwich plate. The following diagram shows these parts.
Part # 23 is the Toyota water jacket fed oil cooler while # 13 is the Lotus sandwich plate. The “U” tube part # 20 is inserted into the hose assembly # 24 to bypass the #23 oil cooler once it has been removed. When assembled in the Elise all these parts appear as in the following photos and an abrasion spot on the “U” tube will form as shown.
The cause of the “U” tube abrasion is due to the tube and hose assembly not being properly insulated and supported so the tube rubs on the oil hose fittings attached to the Lotus sandwich plate. The tube is made from thin walled soft aluminum and will wear through quickly where it contacts the steel fittings which results in a leak and loss of coolant. If left unchecked this coolant loss could easily result in an overheated engine and you being stranded on the side of the road. A damaged “U” tube once removed from the car looks like this...
Lotus seems to have become aware of the problem at some point during production and they started zip tying the tube to one of the oil cooler hose fittings as shown in the next photo, but this may not stop the abrasion and failure of the tube.
I would recommend at your next oil change (or earlier if your Elise has many miles on it) inspecting this tube. If the tube is showing considerable abrasion wear purchase a new one or have the abrasion welded. Whether you replace the tube with a new one or not, be sure to insulate the wear area with a piece of split heater hose and zip ties and then tie off the entire assembly to one of the oil cooler hoses with more zip ties.
The last topic I would like mention is winter storage. Many Elise owners live in winter climates that prevent them from being able to drive their cars during the winter, so here are a few Elise specific tips to ensure your car comes out of winter storage with-out any problems. Depending on your storage conditions, you may need to remove your wheels and tires to prevent damage to the tires. The Yokohama tires supplied from Lotus (both AD07 and A048) can be damaged if left on the car or driven on when their temperature drops below 14 degrees F. Yokohama states the rubber compound of the tires will crack if the tires are left on the car and the tires will become permanently damaged. If your car will be subjected to these temperatures, remove the wheels and store them in a warm place, but do not leave your Elise on jack stands unless the weight of the car is supported through the suspension. If the suspension is left in full droop for an extended period of time, the rubber suspension bushings will become dam-aged from the twisting force applied to them.
If you plan to leave the battery in your car during storage, be sure to attach your battery to a battery tender, or you will have a dead battery by spring. The alarm and immobilizer system will quickly drain the battery and may permanently damage it if it is left that way for the entire winter. Unless you can store your Elise without the alarm or immobilizer set, it is best to remove the battery and keep it attached to a battery tender in a warm place. If you plan to remove your battery, make sure the alarm and immobilizer are turned off before removing the battery cables.
As new service issues come to light I will continue to report them so until next time, enjoy your Elise and I hope you find these tech tips help you to keep your car functioning properly.
