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Lotus Elise / Lotus Exige. Instruction - part 116

Page 13

Lotus Service Notes

2-Eleven

A one-way valve at the oil cooler connection of the 'T'- piece ensures that the oil discharged from the

Accusump is directed into the oil pump and not the cooler. An Electric Pressure Control (EPC) valve ﬁtted at

the connection to the Accusump cylinder, allows cylinder charging when oil pressure is above 35 - 40 psi, and

cylinder discharging at engine oil pressures below 35 - 40 psi. The EPC is also linked to the ignition switch

such that with the ignition switched on the valve is open to allow oil ﬂow, and with ignition off the valve is closed

to retain oil within the reservoir.

Normal Operation

When the ignition is turned on, the EPC valve on the Accusump is opened, allowing the pressurised oil

stored in the reservoir to ﬂow out into the engine and prime the oil galleries and bearings ready for start up.

When the reservoir has been emptied, the pressure gauge on the end of the reservoir will indicate the pre-

charge pressure which should be 7 - 15 psi.

When the engine is started, engine oil pressure will force the reservoir piston back, such that the reservoir

air pressure gauge will indicate engine oil pressure, with the quantity of stored oil dependent on this pressure

at any one time. With cold oil, 80 psi may be seen, but idling at normal running temperature should produce

around 30 - 40 psi. Note that the pressure reading on the reservoir gauge is damped and will lag behind the

actual instantaneous pressure. A pressure relief valve in the end of the reservoir protects the equipment from

over-pressure damage. If oil is seen to escape from this valve, a fault in the lubrication system is indicated, or

excessive rpm have been used with cold oil.

When the engine is stopped, the EPC valve closes and a quantity of oil pertaining to the oil pressure at

that time, will be retained in the Accusump ready for re-starting.

Routine Checks

Be aware that the indicated oil level on the dipstick will depend on the amount of oil stored in the Accu-

sump, which itself is dependent on the both the Accusump pre-charge air pressure and the engine oil pressure

when the ignition was switched off.

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. The pressure

gauge reading will drop during this discharge, but should then register 7 - 15 psi representing the pre-charge.

If necessary, adjust the air pressure using tyre inﬂator equipment on the Schraeder valve adjacent to the gauge

and set to 15 psi. Allow adequate time for the gauge reading to stabilise.

The oil level should now be above the top

mark on the dipstick. To check for correct oil

level, the engine should be started to charge

the Accusump, and run to normal operating

temperature until the Accusump pressure

gauge registers 40 psi. If the engine is already

hot, idle oil pressure may not be sufﬁcient to

open the Accusump valve, and the pressure

gauge will continue to show 15 psi pre-charge.

Increase engine rpm to open the valve. With

the gauge showing 40 psi, turn off the engine.

The EPC valve will then close and trap the

normal hot idle quantity of oil in the Accusump

cylinder.

After a suitable oil drainback pause, the sump oil level may then be inspected on the disptick, and the

level corrected to the top mark. It is important to maintain oil at this level to accommodate the oil transfer into

the Accusump at pressures greater than 40 psi. Be aware that checking the oil level under any conditions other

than 15 psi pre-charge and 40 psi oil pressure will produce inconsistent results.

Oil Changing

Before draining the sump, the ignition should ﬁrst be switched on to open the EPC valve and allow the

Accusump to discharge the stored oil into the sump. Check that a pressure of 7 - 15 psi remains in the Ac-

cusump at the end of this process, and if necessary top up the pressure using tyre inﬂating equipment on the

Schraeder valve next to the gauge and set to 15 psi.

ohs149aB

OIL FILLER CAP

ohs131aB

DIPSTICK

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

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