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Lotus Elise / Lotus Exige. Manual - part 112

Lotus Service Notes

Exige S/C

Page 12

EXIGE S/C.O - MAINTENANCE & LUBRICATION

A Maintenance Schedule for supercharged cars is available under part number LSL460b.

Recommended lubricants are unchanged apart from:

240R & Cup cars: Brake Fluid; Castrol SRF

Fuel; Unleaded 98 RON

Spark plugs are part number ALS3E6015F (NGK PFR7G) with 0.8mm (- 0.1, + 0) gap.

EXIGE S/C.Q - CLUTCH

240R and Cup cars use an uprated clutch cover assembly and a competition speciﬁcation sintered metal fric-

tion plate. No routine maintenance is required other than annual renewal of the Castrol SRF hydraulic ﬂuid.

EXIGE S/C.Z - MISCELLANEOUS

Supercharged models also differ from standard Exige in the following respects:

Engine dipstick tube altered to avoid supercharger.

Relays on engine bulkhead moved to avoid supercharger by-pass capsule.

Charcoal canister moved from bulkhead to bracket on top of chassis right hand rear upright member.

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Lotus Service Notes

Exige S/C

EXIGE S/C.X - RETROFITMENT OF SUPERCHARGER

To retroﬁt the Magnuson MP62 supercharger and related engine systems to the standard Exige, proceed

as follows. Note that throughout this section, the terms 'front', 'rear', 'left' and 'right' when referring to engine

components are used in the convention of the ﬂywheel end of the engine being the rear. The orientation of the

engine as installed, results in the front of the engine being towards the right hand side of the car.

1. Remove the following parts:

- Drain coolant;

- Rear clamshell;

- Charcoal canister, bracket and pipes;

- Spark plug and injector covers;

- Convoluted air intake trunking;

- Throttle body;

- Fuel rail with injectors (keep together); Seal apertures with tape;

- Inlet manifold and moulded foam pads beneath; Seal apertures with tape;

- Breather pipe between crankcase and cam cover; Dipstick tube; Seal apertures with tape;

- Auxiliary drive belt and water pump pulley;

- Alternator top mounting bolt and stabiliser bracket, and swing alternator outwards;

- Engine wiring harness, ECM and mounting plate;

2. With the ECM mounting plate on a bench, mark out and cut the right hand top corner of the plate as shown.

Further cut and drill the removed section to the dimensions shown, and ﬁx to the ECM plate with an M6 x

25 screw, penny washer and plain nut.

3. Fit an engine lifting hook T000T1437S to the LH front of the

cylinder head using bolt T000T1440S and support the engine

weight to allow the RH engine rubber mounting to be removed:

Remove the engine rubber mounting with pressed steel and

alloy brackets as an assembly.

4. To allow access to the rearmost ﬁxing of the engine mounting plinth on the front of the engine, it is neces-

sary to release the exhaust manifold and EGR pipe ﬁxings: Remove the EGR pipe clip from the timing

chain cover. Remove the exhaust manifold upper heat shield. Remove the two outermost nuts retaining

the exhaust manifold. Slacken the remaining 3 manifold bolts.

Release the four bolts and remove the engine mounting plinth. Replace with the modiﬁed version using

original ﬁxings, and with Loctite 5910 (A121L0077H) sealant applied to the ﬁxing by the EGR pipe. Tighten

all four bolts to 52 Nm.

Reﬁt exhaust manifold using Permabond A130 threadlock on the ﬁxings and tighten to 52 Nm. Reﬁt heat

shield using A130 and 20 Nm. Reﬁt EGR pipe clamp to 27 Nm.

5. Remove the engine rubber mounting from the pressed steel bracket and replace with new rubber mount-

ing ALS3E0038F (52 Nm). Reﬁt the engine mounting assembly to the engine and chassis and remove

engine support equipment.

6. Remove and discard breather spout from LH side of crankcase, but retain connector hose. Fit new spout

using original ﬁxings (10 Nm) and reﬁt connector hose. Fit new breather pipe into connector hose and to

cam cover using original ﬁxings. Fit new dipstick tube into position.

7. From inlet manifold jointface on cylinder head, remove and discard the long stud at the rear end of the

face. Fit new M8 x 25 stud (10 Nm) to the central ﬁxing position between ports 2 and 3. Slacken the

screw securing the VVT valve to the LH front of the head to allow it to be re-orientated to clear the new

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Exige S/C

Page 14

manifold.

Fit the new manifold and retain with the original two top ﬁxings using Permabond A130. Do not fully

tighten. Use new ﬂange head bolt A116W5238F with Permabond A130 at the rearmost ﬁxing point. Take

the nut previously ﬁtted on the foremost stud, and ﬁt instead to the new stud at the centre bottom ﬁxing

(with Permabond A130). Take the nut previously ﬁtted on the centre bottom stud, and ﬁt instead to the

foremost stud using A130. Progressively tighten all ﬁxings to 27 Nm. Secure the VVT valve to 10 Nm.

8. Lay the new engine harness in position with the injector portion in the channel between inlet manifold and

cylinder head with injector breakouts uppermost and aligned with the injector ports. Route the harness

between the new breather pipe and inlet manifold, following a tight line down beside the cylinder head

and block to the back of the alternator.

9. Reﬁt the injector rail taking care to correctly seat the injectors. Ensure the spacers are in place before

securing with the 2 x M8 ﬁxings - 20 Nm. Secure the fuel pipe to the cam cover - 9 Nm.

10. Remove the four coil packs and replace the spark plugs with the new PFR7G items. Torque to 18 Nm.

Reﬁt coil packs to 9 Nm.

11. Reﬁt all connectors on new harness.

12. Fit supercharger nose bracket to engine mounting plinth with new M10 x 50 ﬂange head bolt and M10

ﬂange nut hand tight. Fit upper ﬁxing on alternator to nose bracket outer end using the 13.5mm spacer

and M8 x 55 ﬂange head bolt. This deﬁnes the position of the nose bracket. Tighten bracket to engine

mounting plinth to 50 Nm. Remove alternator top bolt to allow supercharger to be ﬁtted.

13. Prepare supercharger: Clean mating faces of supercharger and outlet adaptor using Betaclean 3900. Fit

'O' ring into groove in outlet adaptor and ﬁt to supercharger using 6 off M8 x 25 setscrews with Permabond

A130. On the ﬁxing located inside the adaptor, Permabond should be applied over the entire thread length.

Orientate the adaptor with the outlet pointing towards the rear of the car when ﬁtted. Torque tighten all

ﬁxings to 25 Nm.

Clean mating faces of outlet adaptor and outlet elbow using Betaclean 3900. Fit 'O' ring into groove in

outlet adaptor face. Fit outlet elbow to point to LH side of car using 4 off M8 x 25 setscrews with a pipe

clip bracket secured by both rearmost ﬁxings. Tighten to 25 Nm. Fit double pipe clip into front side of

each of the two brackets.

14. Fit M8 stud B111E6081S into RH top (as viewed on face) ﬁxing position in supercharger inlet ﬂange. Clean

mating face on supercharger and inlet adaptor using Betaclean 3900. Fit 'O' ring into groove in adaptor

face and ﬁt adaptor to supercharger using 2 off M8 x 30 ﬂange head bolts in top positions and M8 ﬂange

nut on stud - all 25 Nm. Disregard 4th position at this stage.

15. Fit original throttle body isolator to inlet adaptor using the clockwise choice of ﬁtting position, with original

ﬁxings tightened to 10 Nm. Fit the original throttle body to the isolator using original ﬁxings tightened to

10 Nm.

16. Mount supercharger: With the pulley removed from the supercharger, slide the nose into the nose bracket

until hard against the machined step. Support to the inlet manifold sliding bushes using M10 x 50 ﬂange

head bolts and Permabond A130, but do not tighten. Tighten the nose bracket socket head pinch bolt to

25 Nm.

17. Loosley ﬁt the supercharger support strut between the inlet adaptor (M8 x 55 bolt with A130) and the clutch

slave cylinder new ﬁxings (M8 x 25 with A130). Tighten the three support strut bolts to 25 Nm. Carefully

tighten the two M10 x 50 ﬂange head bolts to pull in the two spacers evenly to clamp against the super-

charger.

18. Reﬁt the alternator upper bolt and spacer and tighten to 25 Nm. Tighten the lower bolt to 25 Nm.

19. Fit the pulley to the supercharger with the longer boss towards the 'charger. Fit the nut onto the shaft, and

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Lotus Service Notes

Exige S/C

use a strap wrench to hold the pulley whilst the nut is tightened to 61 Nm.

20. Use a 6-point socket on the tensioner arm to allow ﬁtment of the new multirib accessory drive belt around

the pulleys as shown, ensuring that the belt is correctly seated in all the ribbed pulleys.

21. Fit two rubber mountings to both of the chargecooler mounting brackets using spring washers and M8

Nyloc nuts. Fit the LH bracket to the inlet manifold and cam cover using Permabond A130 on both screw

threads. Tighten to 25 Nm. Fit the RH bracket to the inlet manifold bosses in a similar manner.

22. Fit the MAP sensor to the chargecooler using the M6 x 16 setscrew, ensuring that the sensor seal is intact.

Fit the chargecooler to the rubber mounts and secure with spring washers and Nyloc nuts tightened to 25

Nm.

23. Fit the chargecooler intake 'U' shaped duct A128E0008 between the supercharger outlet and chargecooler

using the connector hoses and worm drive clamps. In a similar manner, ﬁt the outlet duct A128E0011

between the chargecooler and inlet manifold.

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