Lotus 2004 ELISE Service Notes page 446

Lotus Service Notes
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
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