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Lotus Service Notes
Concept & Overview
Technical Data
Body
Front Suspension
Rear Suspension
Engine
Wheels & Tyres
Brakes
Cooling
Maintenance & Lubrication
Clutch
Miscellaneous
sn_Exige Supercharged supplement.indd 1
SUPPLEMENT
EXIGE SUPERCHARGED (S/C)
Exige S/C
Sub-Section
Page
Exige S/C.#
2
Exige S/C.TD
3
Exige S/C.B
4
Exige S/C.C
5
Exige S/C.D
5
Exige S/C.E
5
Exige S/C.G
11
Exige S/C.J
11
Exige S/C.K
11
Exige S/C.O
12
Exige S/C.Q
12
Exige S/C.Z
12
Page 1
03/03/2006 11:32:33
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Summary of Contents for Lotus Exige S/C
- Page 1 Lotus Service Notes Exige S/C SUPPLEMENT EXIGE SUPERCHARGED (S/C) Sub-Section Page Concept & Overview Exige S/C.# Technical Data Exige S/C.TD Body Exige S/C.B Front Suspension Exige S/C.C Rear Suspension Exige S/C.D Engine Exige S/C.E Wheels & Tyres Exige S/C.G Brakes Exige S/C.J...
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Page 2: Exige S/C
Lotus Sport workshops at Hethel, and available for the U.K. and certain overseas territories where regula- tions allow. In November 2005, Lotus Sport commenced build of a limited number of Exige Cup 240 cars in road or race specification for selected markets, and differing in detail to the 240R. Then in January 2006, an official production version of the supercharged car, Exige S, was introduced with a simplified specification. -
Page 3: Exige S/C.td
Lotus Service Notes Exige S/C EXIGE S/C.TD - TECHNICAL DATA Where different to standard Exige: Engine Forced induction Magnuson MP62 supercharger with integral by-pass valve. Air/air chargecooler. Maximum boost pressure 0.5 bar (7 psi) Max. power - 240R & Cup 181 kW (243 bhp;... -
Page 4: Exige S/C.b
Each Lotus Sport Exige 240R is individually numbered from 001 to 050, and identified by a Lotus Sport build plate styled after those used by Team Lotus for the Formula One cars. The plate is riveted to the chassis main side rail on the passenger side, and is engraved with the unique Limited Edition number. -
Page 5: Exige S/C.c
Lotus Service Notes Exige S/C EXIGE S/C.C - FRONT SUSPENSION - 240R & CUP Stiffened road springs front and rear are fitted on new Ohlins dampers featuring remote gas reservoirs, adjustable spring platforms and separate adjustments for compression and rebound damping. The spring plat- forms allow for lowering of the car to 120/120mm mid-laden ride height for track use, and the 22 compression and 60 rebound damper settings allow the characteristics to be fine tuned to individual requirements. - Page 6 Lotus Service Notes Exige S/C Page 6 sn_Exige Supercharged supplement.indd 6 03/03/2006 11:32:35...
- Page 7 Lotus Service Notes Exige S/C Chargecooler outlet duct Inlet manifold Chargecooler Chargecooler inlet duct Boss for 5th injector Standard (240R) airbox Supercharger outlet elbow Supercharger outlet adaptor Electronic Supercharger throttle body FRONT Throttle body adaptor le2047a Flexible bellows Adaptor to chargecooler...
- Page 8 Cup cars use 4 special high-flow port injectors, and Exige S cars retain stand- ard injectors. The Lotus engine management system is reprogrammed to suit each engine specification and incorporates additional functions to control the fifth injector (240R) and supercharger by-pass valve. The boost characteristics have allowed the switching point from low to high lift cam profile to be reduced from 6,000 to...
- Page 9 Lotus Service Notes Exige S/C Accusump reservoir Air pressure gauge EPC valve assembly FRONT Mounting clamp to boot floor In-line filter To LH port From oil on sandwich cooler plate pl4015cLR Before checking the oil level, the Accusump pre-charge pressure should first be checked; turn on the ignition to open the EPC valve and allow the stored oil to be discharged from the Accusump.
- Page 10 Lotus Service Notes Exige S/C Supercharger Remove/Refit To remove: Remove the chargecooler together with inlet and outlet 'U' shaped ducts. Remove the throttle body and vacuum/breather hose plumbing. 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.
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Page 11: Exige S/C.g
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 dependent on body colour (see above). 'Lotus Sport' is moulded into one of the spokes of each wheel. Cup and Exige S models use standard Exige wheels finished in hi-power silver. -
Page 12: Exige S/C.o
Lotus Service Notes Exige S/C 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. - Page 13 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.
- Page 14 Lotus Service Notes Exige S/C 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...
- Page 15 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.