2006 Lotus Elise

On October 14, 2011, Lotus Cars USA Inc. notified the Office of Defects Investigation (ODI) that it will conduct a safety recall (11V-510) to address concerns with engine oil cooler lines detaching from its crimped fitting on MY 2005-2006 Lotus Elise vehicles.In its 573 report to ODI, Lotus indicated that they have identified instances where the oil cooler lines would detach from their fittings.Lotus attributes this condition to a majority of single supplier affected parts built from June 2004 to November 2006.Lotus states that the cause of the failure is an inadequate process by which the hose is crimped into its fitting by the supplier.In October 2006 the supplier implemented an improved crimping process.Reports indicated that this condition can occur while driving or while the vehicle is stationary with the engine running.In cases where the failure occurred while driving, oil would be expelled under pressure and could come into contact with the tires and or brake friction surfaces, potentially causing a loss of braking or vehicle control. One crash and one vehicle fire were also reported with no injuries.Additionally Lotus indicated that the same condition can occur in MY 2005-2006 Exige vehicles as well. These vehicles are also included in the recall.The action taken by Lotus is sufficient to resolve the issues raised by this investigation.This investigation is therefore closed.

I HAVE AN INQUIRE IN REGARD TO MY 2006 LOTUS ELISE (VIN [XXX]) OIL LINE ISSUE THAT HAPPENED ON 12/11/13. I WAS DRIVING NORMALLY AND THE ENGINE LIGHT CAME ON ALL THE SUDDEN. I PULLED OVER SHORTLY AFTER. WHILE WAITING FOR THE TOW TRUCK, I ALREADY CAN SEE THAT THE ENGINE OIL WAS LEAKING FROM THE FRONT RIGHT SIDE. MY CAR WAS TOWED TO A LOCAL REPAIR SHOP AND FOUND THAT THE OIL LINE WAS DIS-ATTACHED FROM THE CONNECTOR. I HAD BEEN TRYING TO THE CALLED THE LOTUS USA # 1800-245-6887 SINCE THE INCIDENT (12/11/13). I CALLED ON 3 DIFFERENT DAYS (12/11/13, 12/20/13, AND 12/23/13); CALLED 5-6 TIMES, AND LEFT 3 VOICE MESSAGES TO [XXX] WITH MY NAME, THE INQUIRY, AND MY PHONE #, AND UNTIL TO DATE (11/24/13) NO ONE EVER CALLED BACK. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10557199

Incident

Dec 11, 2013

Mileage

60,200 mi

TL* THE CONTACT OWNS A 2006 LOTUS ELISE. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 11V510000 (ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE). THE MANUFACTURER WAS NOTIFIED AND INFORMED THE CONTACT THAT THEY HAD NO TIME FRAME AS TO WHEN THE NECESSARY PARTS WOULD BE AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 11,300.

NHTSA ID

10458335

Incident

Jan 14, 2012

Mileage

11,300 mi

TL* THE CONTACT OWNS A 2006 LOTUS ELISE. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 11V510000 (ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE). THE MANUFACTURER WAS MADE AWARE OF THE SITUATION AND THE CONTACT WAS AWAITING A RESPONSE TO FIND OUT HOW TO PURSUE REPAIRS. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 13,000. ..UPDATED 01/25/16 *BF UPDATED 01/28/16.*JB

NHTSA ID

10453531

Incident

Feb 1, 2012

Mileage

13,000 mi

TL* THE CONTACT OWNS A 2006 LOTUS ELISE. THE CONTACT STATED THAT THE VEHICLE WAS PARKED WHEN HE NOTICED THAT OIL WAS LEAKING ABNORMALLY. AN INDEPENDENT MECHANIC EXAMINED THE VEHICLE AND ADVISED THE CONTACT THAT OIL WAS LEAKING FROM THE OIL FILTER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 11V510000 (ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 10,000.

NHTSA ID

10453317

Incident

Mar 14, 2012

Mileage

10,000 mi

OIL COOLER HOSE SEPARATED FROM FITTING AT THE SANDWICH PLATE ON THE ENGINE. *TR

NHTSA ID

10450517

Incident

Feb 13, 2012

Mileage

40,000 mi

AS I WAS PULLING ONTO MY STREET, THE OIL LIGHT CAME ON THE DASH. I IMMEDIATELY FOUND A PLACE TO STOP AND PARK THE CAR, AT WHICH TIME I NOTICED THE SMELL OF OIL IN THE CABIN. UPON EXITING THE VEHICLE I NOTICED OIL ON THE FRONT DRIVER'S SIDE TIRE & WHEEL, AND APPROXIMATELY 30 MINUTES AFTER PARKING THERE WAS A LARGE PUDDLE OF OIL UNDERNEATH THE FRONT HALF OF THE CAR. MY ONLINE SEARCH FOR A POSSIBLE CAUSE OF THIS INCIDENT HAS LEAD ME TO BELIEVE THAT I EXPERIENCED A FAILURE OF THE OIL COOLER LINES. *TR

NHTSA ID

10441035

Incident

Dec 22, 2011

OIL COOLER SUPPLY LINE CONNECTED TO THE SANDWICH PLATE WHERE THE OIL FILTER SCREWS IN, ON MY 06 LOTUS ELISE BECAME DISCONNECTED FROM THE COUPLING, SPRAYING OIL EVERYWHERE AND PERMANENTLY DAMAGING MY ENGINE. THE ENGINE ONLY HAS 50K MILES ON IT, AND NOW IT NEEDS TO BE REPLACED. NEW MOTOR, AND LABOR COSTING OVER 6000 DOLLARS TO FIX. THIS IS AN ISSUE THAT SERIOUSLY NEEDS TO BE ADDRESSED BY LOTUS, AS NUMEROUS LOTUS OWNERS ARE REPORTING THIS AND DISCUSSING THIS ON THE ONLINE FORUMS. BEING THE 2ND OWNER OF THE VEHICLE, I AM NOT COVERED BY WARRANTY AND ALL THE REPAIR COST ARE COMING OUT OF MY OWN POCKET. I WISH THERE WAS SOME WAY I CAN GET SOME COMPENSATION BACK FROM LOTUS, AS I ONLY PUT 5K MILES ON THE CAR BEFORE THIS HAPPENED... *TR

NHTSA ID

10424209

Incident

Aug 15, 2011

I WAS DRIVING HOME FROM WORK, AND AFTER ABOUT HALF OF A MILE I STARTED TO SMELL BURNING OIL AND THOUGHT TO MYSELF "BOY, I'M GLAD THAT SMELL ISN'T COMING FROM MY CAR!" I WAS TRAVELING AT ABOUT 55 MPH. I LOOKED IN MY REAR VIEW MIRROR AND SAW A THICK TRAIL OF OIL FOLLOWING ME AND LOOKED AT MY OIL LIGHT AND SAW THAT IT WAS ON. I IMMEDIATELY PULLED OVER. THERE WAS OIL COVERING THE RIGHT REAR TIRE, BRAKE ASSEMBLY, AND SUSPENSION. THE REMAINING TWO OR THREE QUARTS CAME OUT WHILE I WAS CALLING THE TOW TRUCK. THE SHOP MECHANICS SAID THAT THE OIL COOLER HOSE SLIPPED OUT OF IT'S CRIMP AND HE SHOWED ME A PHOTOGRAPH. I FOUND OUT LATER THAT THERE IS NO EASY FIX. ACCORDING TO THE EXPERTS IN THE LOTUSTALK FORUMS, IT'S COMMON FOR THE CRIMPS TO COME UNDONE. ALTHOUGH I HAD SHUT DOWN THE ENGINE IN TIME TO AVOID A COMPLETE SEIZE UP, THE REPAIR COST WILL STILL BE AROUND $2000 TO REPLACE THE HOSES AND CLAMPS. MOST OF THE COST IS FROM LABOR BECAUSE IT'S DIFFICULT TO PULL THE HOSES THROUGH AND THE FRONT CLAMSHELL NEEDS TO BE REMOVED. THERE ARE AFTERMARKET KITS TO REPLACE THESE OIL COOLER HOSE/CLAMP SYSTEMS. I HAVEN'T FIGURED OUT HOW I'M GOING TO DO THE REPAIRS YET BECAUSE THE NEAREST LOTUS DEALER IS $250 MILES AWAY. ALTHOUGH I WAS UNINJURED, I CAN SEE HOW THIS COULD CAUSE INJURIES - EITHER FROM THE BRAKE ROTORS GETTING COATED WITH OIL, FIRES, OR THE ENGINE SEIZING UP IN THE MIDDLE OF A BUSY HIGHWAY. THE LOTUS ELISE IS A GREAT CAR, BUT THE OIL COOLER HOSE CLAMPS IN THE EARLIER MODELS ARE A BIG PROBLEM! *TR

NHTSA ID

10421090

Incident

Aug 19, 2011

Mileage

30,000 mi

Standard information required and procedures to be followed when reporting ECU & TCU faults. There is often insufficient, or inconsistent information received from dealers when reporting ECU & TCU related faults, this can lead to unacceptable delays in repairing vehicles.

There is often inconsistent or insufficient information received from dealers when reporting ECU and TCU related faults. This bulletin aims to standardise the information when filing a claim to After Sales.

Air conditioning compressors failing due to oil starvation. TSB reminds dealers of correct replacement and running-in procedures.

Any unauthorised modifications, including fitment of non-approved after-market air filter resulting in generation of diagnostic trouble codes (DTC’s) P0101 & P1109. We have had several instances where DTC’s P0101 & P1109 had been set and the car recovered into the dealer, only for them to find that the original equipment engine air intake filter had been substituted for a non-approved after-market type (applicable to both dry and oil coated types).

Compatibility of Yokohama AD07 and V105 tire product ranges for the Elise model range.

Recommendation of revision to manual brake bleeding procedure on any Elise models fitted with a brake servo unit. Whilst performing a brake fluid bleeding procedure, it is possible that the brake pedal may not fully return to its released/uppermost position (when being fully actuated as part of the manual bleeding routine) due to vacuum stored within the brake servo unit.