Lotus Europa Manual

Section 1 - Wiring Diagrams

Section 2 - Heating and Cooling
Section 3 - Weber/OER Tuning

Change Log:
Updated 1/14/2011 for Tachometer & Shift Light
Updated 2/22/2011 to show actual EDIS to Coil Wiring
Updated 3/02/2011 to add Weber jet data
Updated 3/12/2012 added Radiator temp switch; updated Weber/OER tuning

3/12/2012 6:56:33 AM © Dean Caccavo - [email protected] 1

 Section 1

Lotus Europa Wiring Diagrams

EZ Wire/ Megajolt / Zetec / Nippon

Denso Alternator / 47 Dash Layout

3/12/2012 6:56:35 AM © Dean Caccavo - [email protected] 2

 Component Layout

Megajolt /EDIS
Behind Passenger Battery
Seat Alternator
Main Wiring Loom
Throttle Position
Serial Connector for
Switch Front Carb Ground
MegaJolt inside
Glove Box Lug

Headlight/
Fan Relays
Fuse Block and Back up
Ground Turn Signal Switch
30 Amp Main
Lug Relays
Fuse Behind Ash
Tray
Gauge Voltage
Stabilizer Attached
Radiator to Temp Gauge Ground Lug
Fan Thermo Behind
switch Passenger
Seat Coil

Ground Lug
Under Fuse
Block
Oil Sender

VR Sensor Under
Header/Flywheel
3/12/2012 6:57:11 AM © Dean Caccavo - [email protected] 3
Dash Layout

Temp Fuel Volts Amp

Shift Lights
Oil High Charge
Turn Signal Rad Fan (2)
Tach Fuel (1) Override Heater (3) Map (4)
Speed
Oil
Ignition Lights (5) Wipers (6)

Ash tray

Glove Box Lock EZ Wire Fuse Block

MegaJolt
Serial Cable
(inside)

3/12/2012 6:56:36 AM © Dean Caccavo - [email protected] 4

Charging and Starter

#52 Solenoid Power Amp

EZ Wire Fuse Block
Red Meter

#55 Coil Pos

Coil Pink
#29 Ignition Switch Ignition

#52 Solenoid Power

#31 Ignition Switch Acc
#33 Ignition Switch Power

#30 Ignition Switch Coil

Red
Orange

Brown

Lucas 3 Pole
Red

Pink

#32 Ignition Switch Start

10 Gauge
Starter Switch

Blue
#44 Alt Exciter
1

White
Purple

30 Amp
2

Fuse
Charge
3 Lamp

10 Gauge
Blue/Red

Red
Blue/White
Solenoid Nippon Denso
Lucas Starter Switch
Alternator
Europa Spares #47SA B
S
Fusible Link
Dean 09/06/2010 Black/White IG L
Odyssey
10 Gauge
3/12/2012 6:56:38 AM Blue
© Dean Caccavo - [email protected] 5
Ignition
Lucas Toggle
Off On
Power Map Option
Ground

Red
Lug Green/Red
Lug 1 2
EDIS-4

#55 Coil Pos

EZ Wire Fuse Block Brown
Pink
Orange
Coil To Tach
Red

Red

Black
White
Blue
Rear Bulkhead Yellow Rear Bulkhead
Red

Black

Blue

Updated to show EDIS to Coil

actual install (Y-B; B-Y) plugs
swapped (near EDIS module)

3/12/2012 6:56:38 AM
Coil
© Dean Caccavo - [email protected] 6
 MegaJolt Lite Jr V4
Ford EDIS-4
Black and Fuel pump
Ground Red in Ground Ground
Shielded to Battery
cable to VR
Sensor
Pink Brown and
Power Orange in
From #55 Shielded
Coil Pos cable to
MegaJolt

Yellow and
Blue +
Purple ground to
Tach Out Coil

VR/Coil
Red – and TPS to
Choke Engine
power not
used
White and
Pink Blue +
Power Serial Power to
From #55 Cable to TPS
Coil Pos Glove Box

3/12/2012 6:56:39 AM © Dean Caccavo - [email protected] 7

Shift Lights

Shift Lights on Dash

Anode side (longer)

470 OHM
Cathode
side (flat)

1
Black 2
Purple Brown
3
Orange Lucas 3 Pole
Starter Switch

3/12/2012 6:56:39 AM © Dean Caccavo - [email protected] 8

Tachometer

Purple
Bullet
Lug
Ground
Lug Spade
Lug

Smiths RVC
Tachometer

1
Red
2 Lucas 3 Pole
Starter Switch
3
terminal 1 is for the power
terminal 2 is for trigger lead which will go to terminal on coil marked 'cb' or earth
terminal 3 is earth ; Source http://dosjebroseven.se/tips.htm

3/12/2012 6:56:39 AM © Dean Caccavo - [email protected] 9

Head Lights
Green
Head Left
Head Right
Light
Light
Tan

High Indicator

High Beam Relay Low Beam Relay

Blue/Red
1 2 1 2

3 Red
3
Tan
Full Size Relay 5 Full Size Relay
1-2 energized 5-3
5
1-2 energized 5-3

Blue/White
High/Low
Lucas
Brown/Red
Switch
LT Blue

EZ Wire Fuse Block

1 2 Lucas 3 Pole Head Red

Headlight Brown Starter Switch
Lucas Toggle 3 4
Off On On 1
5 6 Brown Behind Center instrument Panel

7 8 2
3
3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 10
Turn Signals / Front Park / Rear Brake Lights
LED Indicator

Turn Turn
Park

470 OHM
Park

470 OHM
Left Right
Light Blue Blue
Yellow Green Red Blue

White Green Blue

Yellow
1 4 2 1 4 2
Flasher Unit Flasher Unit
Diode 3 Diode 3
>I Mini Relay
F578B-14B192-AA
5
L
Left Panel
X Yellow
>I
Left Panel
Mini Relay
F578B-14B192-AA
5
L X
Left Panel
Left Panel At rest 3-4; 1-2 energized 5-3 At rest 3-4; 1-2 energized 5-3

Brown Brown

Yellow
Left Panel

Left Panel
Diode

Diode

Turn Signal
>I
>I

EZ Wire Fuse Block Red I I

Purple

Brown

1 2 Brake
Brake Switch
Headlight Orange
Lucas Toggle 3 4
Off On On Turn Green
5 6 Behind Center instrument Panel Orange
7 8 Stop Stop
Turn Turn
3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 11
Dual Filament Left Dual Filament Right
Fuel Pump

EZ Wire Fuse Block

#29 Ignition Switch Ignition

#41 Fuel Pump

Fuel
#31 Ignition Switch Acc
#30 Ignition Switch Coil

Yellow
Orange

Brown

Lucas 3 Pole
Pink

Starter Switch Lucas Toggle

1 Off On
2 1 2

Fuel Pump
Yellow
3

Carter
Passenger Firewall 1 Fuel 2
Odyssey Pump

Ground

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 12

 Radiator and Cabin Fan
31 Ignition Switch Acc
Orange
Fan
Gray
Gauges EZ Wire Fuse Block
Red
Fan
Solid State Voltage
Stabilizer
Gauge
Battery Instruments E Heat
Attached to Temp Gauge
10 Volt to Temp Gauge and Fuel Gauge

Lucas Toggle Lucas Toggle

Off On Off On
12V Power from Rad Fan Override (2) Heater (3)
Oil gauge See
1 2 1 2
AC 1 4 2
page 15 Black
Blue
Center Panel #2 Center Panel #3
AC 5
Black Mini Relay 3
F578B-14B192-AA
At rest 5-4; 1-2 energized 5-3

| | AC
Blue
Behind Center Fan
Fan instrument Panel Black
Gray 1 4 2
Painless
185 on – 175 off
Thermo-switch
#30111 Fan 5
Fan
Gray Fan
Mini Relay
F578B-14B192-AA
3
At rest 5-4; 1-2 energized 5-3
Gray
Behind Center instrument Panel
Summit 10”
3/12/2012 7:39:10 AM © Dean Caccavo - [email protected] 13
Wiper Motor
31 Ignition Switch Acc
Orange
Blue/Light Green

EZ Wire Fuse Block

07 Wiper Power Wipers Lucas Wiper

Slate Motor
1
Lucas Toggle 2

Brown/light green
Off On On 3
1 2 4
3 4 Relay 5
Green
5 6 30 87a
7 8
87
Lucas Off-On-On Toggle Switch 85 86
Europa Spares #119

Standard 5 pole Relay Red/light green

Lucas 2 Speed Wiper Motor with Park Green

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 14

Oil Light, Oil, Fuel and Temperature Gauges
31 Ignition Switch Acc
Orange
EZ Wire Fuse Block

Gauges
Red Gauge
Solid State Voltage
Oil Light Stabilizer

Battery Instruments E
Attached to Temp Gauge
12 Volt 10 Volt to Temp Gauge and Fuel Gauge
Lt Blue

Temp
12V Power to Radiator Fuel
Thermo Switch See page 13 Gauge
Oil Gauge
Blue
Gauge

Green
Engine
Lt Blue

Sender
Remote
Located under Intake Sender Light Green
Remote Remote
Manifold on Zetec block (was trunk light)
Sender Sender
Corrected to show Fuel Located on Remote Oil
Gauge off 10Volt and Oil Filter Housing
Located in Thermostat
Gauge off 12 Volt ISSPRO RA9XXX Sender 240- Output Hose
33 Ohm in left Fuel Tank
240 = empty; 33 = full
3/12/2012 7:03:25 AM © Dean Caccavo - [email protected] 15
 Lotus Europa Wiring Diagrams

Reference Material

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 16

 MegaJolt Lite Jr V4
Ford EDIS-4

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 17

 Voltage Stabilizer – Solid State
Solid state voltage regulators are inexpensive, but they may be difficult to find locally. The easiest places to purchase them are online.
"Google" the part numbers to identify potential suppliers.

National Semiconductor's "LM2940T-10.0" and NTE Electronics' "NTE1953" are low dropout (LDO) solid-state voltage regulators. If you supply
either of them with a DC voltage between 10.5V and about 30V, they will provide a constant output voltage of 10.0V. Similar to an old-
fashioned bimetallic Voltage Stabilizer, they can't boost voltage: so if the supply voltage drops to below about 10.5V, these LDO's will
"dropout" and simply pass through whatever supply voltage is available.

Note: there are other alternative voltage regulators that could also be used. One example is Texas Instruments' part number "UA7810CKCS"
(a.k.a. "7810" or "LM7810") which frankly you're probably more likely to find at your local Radio Shack. The main advantage of the National
Semiconductor or NTE Electronics devices is their somewhat lower dropout specification.

Also needed: just a few basics including a soldering iron, solder, about six inches of insulated wire, heat shrink tubing (or possibly electrical
tape), etc.

Optional extras: a small LED lamp and a 1000 ohm resistor.

Directions
1. Disconnect the car's battery and remove the original Voltage Stabilizer from the car. (Note: the Voltage Stabilizer is mounted on the
drivers-side firewall just above the steering column.)

2. Open the voltage regulator by carefully prying back the tabs that clamp the metal cover to the plastic base.

3. Cut and remove the old bimetallic regulator mechanism, being careful to leave enough of the two terminals for soldering wires onto them
later.

4. Prepare your solid-state voltage regulator by cutting off the center of its three terminals. (This terminal is nominally a "ground"
connection, and it would be redundant with the mounting tab in our installation. They're connected internally...)
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5. Using a short length of wire, jumper between the solid-state voltage regulator's VIN (12V in) terminal to the "B" terminal on the plastic
base. Carefully solder both connections.

6. Using a short length of wire, jumper between the solid-state voltage regulator's VOUT (10V out) terminal to the "I" terminal on the plastic
base. Carefully solder both connections.

7. The LED indicator is optional. Its purpose is just to show that the system is powered and grounded, and that the voltage regulator is
functioning. The LED is connected at one end to the voltage regulator's 10V "OUT" terminal, and at the other end it's connected to ground
through a 1000 Ohm resistor.

8. To function properly, the solid-state regulator must be electrically well-grounded to the rest of the vehicle. Accomplish this by (first)
connecting it to the voltage regulator's metal cover with a machine screw and nut. Note: the voltage regulator itself must in turn be
grounded to the car by its mounting. If the fasteners are corroded or dirty, they should be cleaned at this time.
3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 18
 Lucas 2 speed plus park wiper

http://www.vitessesteve.co.uk/LucasStuff/LucasStuff2.html
3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 19
On most ND three pin plug style alternators the pins are marked as "L" / "S" / "IG" The only other connection is usually a large single post terminal
marked "B" This is the main wire connected to your battery and is hot at all times.

The three others are fairly easy to understand.

"IG" This is the Ignition wire and issues the "wake up" to energise the circuit when ignition is switched on

"L" This terminal is connected through to the charge warning light on your instrument cluster

"S" This terminal is connected to your battery source and is hot at all times, it may even be connected to the main wire on the large B terminal in
the loom but more often to the battery through a fusible link

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 20

 OE Smiths Fuel Sender Operation
Smiths

Smiths

ISSPRO

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 21

 Section 2

Lotus Europa Heater/Radiator

Water Routing/Diagrams
Mac’s Aluminum Radiator/ Aluminum
Transfer Tubes/ Zetec / Relocated
Heater Control for 47 Dash Layout
Gates Hoses

3/12/2012 6:56:40 AM © Dean Caccavo - [email protected] 22

Component Layout
NAPA Gates Gates ID
9202 22569 42612569
7868 21162 42611162
8393 21703 42611703

Radiator
Radiator
Fan Thermo Smiths
switch Gauge Temp
Sensor
Heater

21569 1999
Contour

21569
2001 Thermostat

ZETEC

Heater
Control Water pump
MegaJolt GM
Temp Sensor

Heater
Valve

Expansion Tank

3/12/2012 7:42:00 AM © Dean Caccavo - [email protected] 23

Zetec Thermostat Housing Modification
1999 Ford Contour 2.0L thermostat housing
installed on 2001 Ford Zetec 2.0L head to provide
a 3/8 NPT fitting to accept a GM Coolant
Temperature Sensor GM Sensor/
3/8 NPT
Not Ford
Replacement requires:
1 8592 Housing
1 8592 Outlet
1 8575 Thermostat
1 W700319-S300 O-Ring

1 GM Coolant Temp sensor

1 GM Coolant Temp sensor connector
Ordered from Boost Engineering
Same as GM part number 12146312

Note: 2001 Zetec Ford

1/8 NPT;
Cylinder Head
not used
Temperature Sensor
(not pictured) is also not
used; resistance values
are outside the
expected MegaJolt
range.

3/12/2012 6:56:41 AM © Dean Caccavo - [email protected] 24

 Zetec Cooling System Diagram

http://www.toyne.org.uk/docs-cooling.html
3/12/2012 6:56:41 AM © Dean Caccavo - [email protected] 25
 Section 3

Lotus Europa Weber/OER Setup

Jet Selection and Tuning

3/12/2012 6:56:41 AM © Dean Caccavo - [email protected] 26

 OER Jet Setup
Jets Initial 4/16/2011 4/17/2011 4/17/2011 4/22/2011 4/30/2011 Current
(1/6/2012)
Emulsion F4 F11 F11 F11 F11 F11 F11
Main 145 145 145 145 145 145 145
Air 155 170 155 155 165 160 160
Corrector
Idle F950 F955 F955 F855 F855 F855 F855
Chokes 36 36 36 36 36 36 36
Pump 40 40 40 40 40 40 40
Idle Screw 1 turn 1.25 turns 1.25 turns 1.25 turns 1.25 turns 1.25 turns 1.25 turns
Air Filter None None None None None None None
Screens On Off On On On On On
Float Level Baseline -2 turns -2 turns -2 turns -2 turns -2 turns -1.5 turns
-turns from (lower) (lower) (lower) (lower) (lower)
Baseline
Comments Too lean Too rich Too Rich Stumbles on Good all Good all around
above 3000 across all over 3000 tip in around –
RPMS Stumbles on
hard lefts

3/12/2012 7:57:13 AM © Dean Caccavo - [email protected] 27