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Lotus Eleven/Elise/Exige. Manual - part 130

Lotus Service Notes

2-Eleven

Page 14

The oil can then be drained in the usual way, with the quantity contained in the oil cooler lines disregarded

for the purposes of routine maintenance. If an engine failure has occurred, with possible debris contamination

of oil hoses and coolers, it is recommended to replace both oil coolers, and to replace or thoroughly ﬂush the

feed and return hoses. At each service interval the in-line ﬁlter gauze in the hose between the Accusump and

'T'- piece, and located in the RH rear wheelarch, should be renewed.

After renewing and pre-ﬁlling the engine oil ﬁlter, reﬁll the sump to about 10mm above the top mark on the

dipstick. Start the engine and allow to idle. Do NOT rev the engine or drive the car. The Accusump will take

up to 2 litres of oil from the sump to store within the cylinder. Continue to idle the engine until the Accusump

pressure gauge drops to 40 psi (as the oil warms) and then switch off the engine. Top up the oil to the top

mark on the dipstick.

Supercharger Remove/Reﬁt

To remove:

1. Remove the chargecooler inlet and outlet ducting.

2. Remove the throttle body and vacuum/breather hose plumbing.

3. Using a 6-point socket, relieve auxiliary belt tension and remove the auxiliary belt. Remove the alternator

top mounting bolt, slacken the lower, and swing down the alternator. Release the dipstick tube from the

supercharger.

4. Using a strap wrench, remove the supercharger pulley retaining nut, and slide off the pulley.

5. Remove the support strut between the throttle body adaptor and the clutch slave cylinder. Slacken the

pinch bolt securing the supercharger to the nose bracket. Remove the two bolts supporting the super-

charger to the inlet manifold and withdraw the supercharger.

To reﬁt:

1. With the supercharger nose bracket bolted to the engine mounting plinth, ﬁt the upper ﬁxing on the alter-

nator to the nose bracket outer end (with 13.5mm spacer). This deﬁnes the position of the nose bracket.

Tighten bracket to engine mounting plinth to 50 Nm. Remove alternator top bolt and swing down to allow

supercharger to be ﬁtted.

2. 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 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.

ohs129

ohs135

SUMP DRAIN PLUG

OIL FILTER

Page 15

Lotus Service Notes

2-Eleven

3. 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.

4. 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.

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

slave cylinder 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 supercharger.

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

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

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

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

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

9. Reﬁt other components in reverse order to removal.

Note areas of change compared with standard models;

Engine dipstick tube altered to avoid supercharger.

Crankcase breather pipe altered to avoid supercharger.

Relays on engine bulkhead move to avoid supercharger by-pass capsule

Belt tensioner

spring/damper

Water pump

Supercharger

Slave pulley

Belt tensioner

Alternator

Crankshaft pulley

pl4103cc

Lotus Service Notes

2-Eleven

Page 16

Supercharger Nose Assembly

If the supercharger input shaft oil seal should be damaged or found to leak, the complete nose assembly in-

cluding the nose housing, shaft, bearings and seals should be replaced as a unit by the following procedure:

Parts Required

Supercharger Nose Assembly A128E6020S 1 off

Oil Fill Kit A128E6014S 1 off

1. Remove the complete supercharger assembly from the engine (see above).

2. Use a strap wrench to hold the pulley, and remove the pulley nut. Use a three leg puller to withdraw the

pulley from the shaft. Apply forces only to the pulley and shaft end. Other techniques may damage the

housing or internal components.

3. Provision for collecting the contained oil before removing the 8 bolts securing the nose housing to the

main supercharger body. To separate the nose from the body, expanding jaw pliers should be used in the

recesses provided around the ﬂange. Do not pry between the mating faces, or damage will be caused

and oil leaks result. Drain all the old lubricant from the gearcase and discard appropriately.

4. Stand the supercharger body on end with the gearcase uppermost. Discard the old synthetic drive cou-

pling, and ﬁt the new part supplied in the oil ﬁll kit onto the three pegs on the rotor drive gear. Check that

the two alignment dowels are ﬁtted in the supercharger body ﬂange.

5. Fill the gear case with 120 ml of Magnuson Products Supercharger oil as supplied in the oil ﬁll kit.

6. Clean the mating face on the supercharger body and on the new nose housing, and apply a bead of Loc-

tite Eliminator Sealant, supplied in the oil ﬁll kit, around the whole of the joint face on the nose housing,

looping around each of the ﬁxing holes.

7. Before attempting to ﬁt the nose housing, ﬁrst align the three pins on the input shaft with the vacant holes

in the drive coupling. Place the nose housing into postition, and ensure that the two alignment dowels

engage with their corresponding holes. It may be necessary for the casing bolts to be used to pull the two

housings together.

8. If re-using the casing joint bolts, the threads should be thoroughly cleaned before applying Loctite 242 or

equivalent medium strength threadlocking compound. New casing bolts are pre-treated. Fit the eight bolts

and tighten progressively to pull the joint evenly together. Finally torque tighten to 27 Nm in the pattern

shown.

9. Fit and secure the oil service plug, and position mark. Reﬁt the supercharger.

Tightening sequence

e233

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Lotus Service Notes

2-Eleven

2-ELEVEN.F - TRANSMISSION

Clutch

The 2-Eleven is ﬁtted with an uprated clutch cover assembly rated for a maximum torque of 362 Nm, and

which enjoys a mass reduction of 0.6 Kg over the regular cover. Also ﬁtted is an uprated friction plate which

uses 4 steel compression springs in the cush drive hub, in place of the regular item's 4 rubber blocks.

Differential

The 2-Eleven is ﬁtted as standard with an 'open' bevel gear differential, supplemented by switchable Lotus

Traction Control (LTC), with an option package of variable LTC with Launch Control. For full details of these

electronic systems, refer to Section 2-Eleven.M

Two types of optional Limited Slip Differential (LSD) are also available.

Torsen Type: A Torsen (TORque SENsing) gear type LSD limits the speed differential between the two rear

wheels by mechanically distributing the applied torque in accordance with the available grip at each tyre. The

LSD uses worm wheels to interconnect the two output shafts and uses the poor torque reversal efﬁciency

of this type of gearing to ensure that both wheels are always supplied with driving torque. This feature can

enhance vehicle performance in some competition events, and help maintain mobility in some types of soft

ground condition.

Apart from the taper roller bearings supporting the differential in the transmission case, the LSD is not

serviceable. For details of bearing preload adjustment, refer to Service Notes sub-section FJ.6. There is no

special oil requirement for the Torsen LSD. All factory supplied transmission assemblies originally built with

Torsen LSD are identiﬁed on the bar code label applied to the top surface of the transmission case; The 3rd

character of the 7 digit code is 'O' for open differential, and 'L' for limited slip.

Plate Type: A competition type friction plate LSD made by TRD is available in both '2 way' and '1.5 way' variants.

This type of LSD uses a pack of friction clutch plates between each differential output gear and the differential

carrier. The load applied to the clutch pack is proportional to the input torque via a cam and ramp angle design

incorportated between the 4-pinion spider (driven by the crownwheel) and the two clutch pack assemblies. The

'stiffness' of the LSD operation is dependent on the ramp angle which may be speciﬁed on ordering. A '2 way'

LSD uses the same ramp angles for drive and overrun to provide similar slip control in both conditions. A '1.5

way' LSD uses different ramp angles for drive and overrun to reduce the clutch pack load on braking. There is

no special oil requirement for the plate type LSD, but to maintain design performance, inspection and cleaning

of the plates should be carried out every 15,000 miles (25,000 km) by a competent agent.

2-ELEVEN.G - WHEELS & TYRES

Optional on the 2-Eleven are 240R type lightweight forged alloy 5-spoke roadwheels, which at 7x16 and

8x17, are ½ inch wider, front and rear, than the standard Exige wheels, but retain the standard insets of + 31.3 mm

and + 38.0 mm. The wheels are ﬁnished in either Satin Black or High Power Silver, with 'Lotus Sport' moulded

into one of the spokes of each wheel. The Lotus speciﬁc, regular Exige Yokohama A048 tyres, identiﬁed by

'LTS', are ﬁtted as standard. Each wheel is retained by four standard Elise/Exige spline head 60 degree taper

seat bolts, for which a splined adaptor tool is stowed in the vertical tube of one of the roll-over bar backstays.

No security coded wheel bolts are used.

Note that these forged alloy wheels incorporate a steel centralising sleeve to locate onto the hub spigot,

and is normally retained in the wheel. A smear of copper grease on the spigot will help prevent corrosion be-

tween the hub and sleeve causing the insert to become separated from the wheel.

2-ELEVEN.J - BRAKES

The anti-lock braking system is uprated in the following respects:

Motorsport brake pads (Pagid RS14) are ﬁtted front and rear together with cross-drilled brake discs;

Steel braided brake hoses ﬁtted all round;

Optional Castrol 'SRF' synthetic racing brake ﬂuid. Over 500°F boiling point. Dot 4.

Brake callipers painted yellow.

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