SUPERCHARGER Lotus Sport – Fitting Instructions Supercharged
Contents
1. 32 EMT EE 0 8B ING 33 ACIDIR De M 15450 SUO arises cic casas cae sc X 34 ACIDI ROOT 35 ACTIVITY CHEC E 39 TN 36 t 13 Page 3 of 39 gt P N ALS3T0008F SUPERCHARGER PROCESS 27S Version 1 SHEET SEQ ACTIVITY PREPARATION SPARK PLUGS Following instructions in service manual A120T0327J and 3 Toyota manuals RM733E and RM929E i uic Tt 3 ds lt RAEE we r WES 10 Remove2. 20 been achieved 60 Clip the 2 off double fir tree connectors into the brackets attached to the outlet port 18 x 25 FL HEAD BOLTS 20 When fitted ensure that they run along side of the supercharger7 30 Ensure that the fitted outlet bore of the ports points away form the supercharger nose 40 Ensure that ring is intact and correctly positioned PARTNUMBER PART DESCRIPTION L QTY PEG TORE eer ALS3E0029F Supercharger Outlet Port Machining Torque Tooling Reference 25Nm fondue wrench 20 CLS3LO008F Fuel Pipe Clips 2 60 120 63245 BOLT FLANGE HEAD M8 25mm 4 Page 17 of 39 P N ALS3TOO08F B MEAM SUPERCHARGER PROCESS SHEET ACTIVITY M8 STUD TO SUPERCHARGER 10 Fit M8 stud into fixing location 20 Torque tighten fixing to specified torque 30 Green paint mark head of fixing once correct torque has been achieved CAREPOINT QUALITY STANDARD 30 Ensure that O ring is fitted correctly onto dipstick tube L SEQ PARTNUMBER PART RART NUMBER PARTDESCRIPHON eer DESCRIPTION LEG J TORQUE TORQUE ees Torque Tooling Refernce 25Nm TOUS weg So wrench T B111 Stud M8 1 Page 18 of 39 P N ALS3TOOO8F Version 1 20 Using CLEAN PROCESS 1 clean area on mating surfaces between supercharger inlet manifold and the rear of the supercharger 30 Cut ring to perimeter lengt
3. YER EN Yea Fh ER YHP CERE Ho 16 ACTIVEEY SUB ASSEMBEYX SUPERCHARGER SWAN NEC 17 ACIIVIIY MSSIUDTOSUPERCHARGENR CHEN CUP EN IE YR REP VY 18 ACTIVITY SUB ASSEMBLY SUPERCHARGER INLET MANIFOLD 52 tette ears EE Naa YN E0002 Ya epe L a 19 V TE ES a WS OD SEE LAREDO E E 21 ACTIVITY FIT SUPERCHARGER IO ENGINE itis esto haa RE PIE TVI2 NN EEX EE VUE XY FEX YR eT eda EXE VERI GENI E EXPE LYRA QUIS CEXR EUER OE BRETT AVE EE EAE FER VER EE POLEN 22 ACLIN RE A INA TOR N E 20 VY FULLELEY SUPERCHARGER 23 c 24 ACTIV
4. TORGUEJ eee BLS3E6035F T Map Sensor BLS3E0046F Intercooler 10 ALS3E6067F M6 X 16 Bolt 1 20 ALSSE6059F Isolation Bushes 4 30 BLS3E6043F Samco Hose 2 1 2 ID 60mm 4 40 53 0044 Intercooler Left Hand Pipe 1 40 ALS3E0045F Intercooler Right Hand Pipe 1 60 BLS3E0050F Retaining Clamp Bellows 2 50 ALSSE6060F Hose Clamps 8 Page 34 of 39 ALS3T0008F SU PERCHARGER PROCESS 4 427 75 Version 1 SHEET v ACTIVITY ROOF 10 ouper glue D section roof seal across the rear edge of the roof the existing roof will already have a two piece seal in place remove ad place new seal across entire width 20 Remove single engine cover strut from rear clamshell 30 Bond 2 off new brackets to recess between tailgate grille apertures and 2 off new brackets to rear clamshell allow to go off 40 Fit gas struts check operation close engine cover 50 Re attach the rear clamshell to vehicle CAREPOINT QUALITY STANDARD SEQ_ PARTNUMBER PART NUMBER PARTDESCRIPTON QTY FC 1 TORQUE TORQUE A117U6007F Seal D section self adhesive hard top rear 1 E ALS3B0023F Brkt Gas Strut Mtg Engine Cover 2 30 ALS3B0024F Brkt Gas Strut Mtg Clamshell Rh 1 30 ALS3B0025F Brkt Gas Strut Mtg Clamshell Lh 1 40 CLS3B0026F Gas Strut Tailgate Supporting 2 Page 35 of 39 nup SUPERCHARGER Sem Sor CIF 7 Technical Bulletin CUP240 01 Class 3 December
5. vdusvkkEveYev eu Y Yvexeuqvie ex YE kERVe Yeu RXXVRETEeYxE CE FN CDREUEXN TEX ERR YER V MER YR CE CUL aL RE TUER UFREV ER ed do EDAX KEXVENE YE E EA YVES EY Re ua eda 6 AC nt Dn En Entum mts hn DE eeu 7 ENCIN SOUNT ec Hn 8 COVER c M 9 ACFIYID MANIFOLD S EUD c 10 5 84 UR 2 04 9 PRL LALER MOUNTS HO Da 11 7 5 84 V TE PEE OI DLP CE LL E 12 X8 Elo QE DENIED P 14 ACIDITY ca cee OR et o d Ord nan n dni Oden dnd UV VIV Vna P 15 ACTIVITY SUB ASSEVIBLY SUPERCHARGER OUTLET Cone
6. 70 Align fixing holes in fuel rail with fixing holes in cylinder head Thread 2x 8 Fixings retained in through holes in fuel rail and hand start into cylinder head 80 Obtain M6 fixing removed earlier Thread fixing through hole in fuel pipe AN Em Y MM and hand start into threaded aperture on cam cover ENSURE THAT THE EA NA cs x 90 Using tools supplied Torque tighten 2x M8 fixings to fully secure fuel rail INJECTOR BREAKCLITS DEEP E to cylinder head ARE PACING UPWARDS n fy uw A t 100 Using tools supplied Torque tighten M6 fixing to fully secure fuel pipe to AND THE FUEL RAIL RE FIT a pus cylinder head THE FUELRAIL ENSURING EA EM M E THAT THE EREAKCAITS AL RDUM m nij 110 Once required torque s have been achieved Green paint mark across REACH CONNECTORS RT Telit mr P head of each fixing CAREPOINT QUALITY STANDARD 30 Ensure that the injector seals are seated correctly when re fitting the fuel rail 70 Ensure that when the harness is being connected to the fuel rail plugs are clicked home 80 Ensure that when connecting harness that the plug is clicked home SEQ PART NUMBER PART NUMBER DESCRIPTION EAN DESCRIPTION TORQUE TORGUE TOOLINN A129E6000F Injector Page 14 of 39 P N 153 0008 SU PERCHARGER jn c f Version 1 ACTIVITY ECM PLATE It is
7. 100 Torque Tooling Reference 18Nm Tas We OM Wrench 120 a Torque Tooling Reference 9Nm Torque Wrench Page 4 of 39 P N ALS3TOO08F Version 1 SUPERCHARGER PROCESS SHEET ACTIVITY REMOVE FUEL RAIL 10 Undo the 3 fixings that secures the fuel rail into position 20 Remove the fixings and place aside for re fitment Remove the fuel rail ensuring that the seals stay in the 30 ports of the engine and are not removed with the fuel rail itself UMGO 3 FIxIKIGZ TO REMOVE FLEL RAL FRO ENGINE CAREPOINT QUALITY STANDARD 30 Ensure that the seals remain and are not removed with the rail PART NUMBER PART DESCRIPTION TORQUE TOOLING Page 5 of 39 ALSSTOO08F S U p E RCH ARG E R jn Version 1 Sor CIF 7 ACTIVITY THROTTLE BODY ALTERNATOR 10 Using hose clamp pliers release spring hose clip on 2 breather hoses that are attached to head of the engine 20 Remove hoses from the head of the engine 30 Undo the 4 fixings on the front face of the throttle body Remove fixings and place to UNDO SPRNG CLIPS REMOVE 2 one side m BREATHER HOSES AS 40 Also undo and remove the 2 fixings on the underside of the throttle body and remove SHOWN bracket 50 With throttle body still attached place still connected out of way 60 Remove the top fixings that secure the alternator stabiliser bracket to the alternator and engine and slacken off the lower fixings but do not remove Swin
8. 2 CAR ST LY ABOVE THE n um EN hn OM THE THE M FRONT OF THE i Al ATF Cn ET E PAF SHO CAREPOINT QUALITY STANDARD 50 Crank sensor harness will be refitted to new dipstick tube LSEQ PART NUMBER PART Lu PART DESCRIPTION i E JG EC TORQUE TOOUNG Torque Tooling Refernce 25Nm wrench Page 31 of 39 ALSSTOO08F SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY INTERCOOLER DUCTING 10 Taking the Bellows to Intercooler Duct score the inner section as shown below with knife prime the surface with BetaPrime 5404 and apply a bead of Betaseal 1701 sealer to the inner surface it is necessary tom cut to nozzle of the betaseal gun to 45 degrees to sensor proper application of bead on the side that mates to the intercooler 20 Press into place and secure using masking tape Ensure no gaps are present and set aside requires 24hrs to set 30 Fettle the rear clam for duct dry fit off the car to start with Fit the rear clamshell onto the vehicle taking care with the paint work 40 Sit the Intercooler onto the bobbins do not secure lt gt 7 CAREPOINT QUALITY STANDARD 30 Ensure that O ring is fitted correctly onto dipstick tube EON PARTNUMBER PARDDESERIPIION Ere LENA TOOLING O ALS3E0053F Bellows to Intercooler Duct Torque wrench N A BetaPrime 5404 N A Bet
9. into position 40 Re fit cam cover breather hose to throttle body where previously removed 50 Connect cam cover breather hose to inlet manifold CAREPOINT QUALITY STANDARD EN d PART Lu eee PARTDESCRIPHON PARFDESGBIPTION EGIT TORQUE TORQUE Torque Tooling Refernce Hose moomo ___ pliers Page 25 of 39 P N 153 0008 SU PERCHARGER j 4 4 47 2 Version 1 ACTIVITY HARNESS WIRING ROUTING amp CONNECTORS Obtain Coil Pack breakout from main harness at Oil Filler cap end of cylinder head Route coil pack breakout along side of cylinder head and into groove along camshaft cover ensuring harness is tucked neatly down between threaded studs and rear of groove Engage four connectors on harness breakout into plugs 30 on corresponding coil packs on camshaft cover as shown in visual Obtain single breakout from main harness at oil filler cap 40 end of fuel rail and engage into camshaft position sensor on front of cylinder head Lr d ES Obtain four connectors from portion of main harness ROUTE THE HARNESS ALONG THE REAR OF MEAS _ A 50 under fuel and engage into plugs on corresponding THE COIL PACKS AS Se OVW THEN CONNECT i VS injectors as shown in visual THE BREAKOUT TO CORRES ONDING 9 WX o ium Obtain VVTI breakout from main harness at alternator PLUGS SHOWN EU o co o SEE 60 endoffuelrail and engage into VVTI sensor on front
10. the engine block Once removed place fxings aside for re fitment 30 Remove breather mount housing from engine and discard 40 Collect new breather mount bracket 50 Fit breather mount to engine block where discarded one was fitted Using 3 fixings from previous fit housing to engine block Torque tighten fixings to specified torque be da 60 Green paint mark head of each fixing once correct REMOVE ORIGINAL XREATHER q i toirque has been achieved MOUNT HOUSING AHD DISCARD QUE Pw t 70 Collect prevously removed lower breather hose Proceed DO HOT DISCARD FRINGS hcc ELA j to remove 10mm from each end of the hose using hose poe 80 Push fit the lower breather hose into correct orientation P this will be judged by the position of the upper brather eis Wr oA LL _ pipe to cam cover HOSE NTO CORRECT TM et eit O o 19 90 Secure breather hose to breather mount using the clamp ORIENTATION AND SECUREWITH EL SPRING CLAMP ar E T F CAREPOINT QUALITY STANDARD Eid cg PART NUMBER PARTDESCRIPHON p ART DESCRIP TION Om TORQUE TORQUE Torque Tooling Reference Hose Hess damp Ses et pliers CLS30058F Breather mounting block 1 60 N a Torque Tooling Reference 10Nm Torque 80 N a Torque Tooling Reference Hose cutters 100 N a Torque Too
11. 2005 Vehicles Applicable Lotus Sport Exige Cup vehicles converted with dealer supercharger fitting kits Title Inter cooler Ambient Air Intake Modification Roof amp Rear Clam Reason Track Race owners wishing to optimise inter cooler efficiency might wish to consider the following detail changes From recent tests conducted on track by Lotus Sport it was found that it was possible via some simple bodywork modifications to increase the efficiency of the inter cooler Typically opening out the apertures resulted in an increased frontal roof intake area of 20 which thus resulted in an inter cooler efficiency increase of 15 20 Action Modify roof scoop air intake and rear clam intake apertures A copy of the modification instructions has been enclosed for each customer that owns a kit fitted by Lotus Sport Note 1 This modification is for track use only 2 Existing restrictions regarding warranty cover for race competition activities will still apply See warranty manual for clarification 3 No warranty claims for labour fitting or other will be accepted Page 36 of 39 P N ALS3TOOO8F SUPERCHARGER jn Version 1 ARDS SLIGHTLY REMOVE UPWARDS ACTIVITY 10 Remove Roof From Vehicle and place on suitable worktop surface 4 SEQ 20 REMOVE FASTENERS F 20 Remove the upper plastic fasteners A100W6479F from the grille and discard 30 Slide the grille upwards and out noting two location feet on the grille
12. 40 Using a suitable file fettle out to the intake return edges this should involve removing about 2 3 mm from the lip is at the clients discretion as too how much should be removed If Roof Scoop Grille is already installed go to sequence 20 if not go to sequence 40 SEQ 40 FETTLE OUT INSIDE OF Wiii TOO RETURN EDGE p pu ELITS F TILED OUT APEBATURE LP 27 Ge TES T CAREPOINT 10 Do not attempt to remove the grille with the roof in situ 10 30 Do not attempt to remove the grille by from the front leading edge of 20 the grille This will damage the body and paint work 40 Wear appropriate protective equipment mask gloves and goggles when 30 sanding the roof area 40 should be taken when fettling not to chip crack or damage the 40 surrounding paint TOOLING 10 _ _ 12 X 1 FLAT FILE 12 X 0 5 OD ROUND FILE STANLEY KNIFE SCISSORS MASKING TAPE Page 37 of 39 ELOTE 1 SUPERCHARGER PROCESS SHEET ACTIVITY 10 With the rear clamshell in situ mask of the leading edge of the rear clam shell around the air intake ducting to prevent damage to paint and bodywork Note the 2mm proud lip that runs along the lower leading edge 20 Fettle the return edge down so that it is flush with the lower leading edge of the air intact aperture 30 Fettle both left hand and right hand edges to en
13. BER Pan n L QTY LEC M Bolt M10 X 50 Hex Flange E Nut M10 Flanged 30 Bolt M8 X 1 25 1 30 Brkt Nose Mtg 1 40 Bolt M10 1 58Nm Torque Wrench Page 20 of 39 ay ALS3T0008F S U PER C HAR G ER m K Cum gt Version 1 ACTIVITY FIT CAM COVER BREATHER 10 Collect relevant fixings and parts required for operation 20 Using new breather pipe fit into lower section of rubber breather pipe Fit upper section of breather pipe onto 2 studs on cam cover Using 30 fixings previously removed secure pipe to cam cover Tighten fixings Using hose clamp pliers secure lower breather hose to upper F i r 1 Ar z P 4 i E 40 BREATHER PIPE TO a ul M iil n aw breather pipe with hose clamp CAM COVER FIXINGS A aA UPPER BREATHER PIPE TO LOWER BREATHER PIPE SECURE WITH Be HOSE CAREPOINT QUALITY STANDARD SEQ PART NUMBER PART NUMBER PART DESCRIPTION TORQUE TOOLING BLS3E0055F Tube breather 1 E Torque tooling Reference Hose Clamp Pliers Page 21 of 39 ALSSTOO08F SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY FIT SUPERCHARGER TO ENGINE 10 Collect require parts for operation 20 Slide supercharger nose into the nose bracket ensuring that its hard against the nose bracket Secure using 2off M10 x 50 Flange head bolts with permabond A130 Do Not tig
14. CAREPOINT PART DESCRIPTION 20 BLS3E0047F Bracket Intercooler Mounting RHS 1 30 A912E7033V Sealant Permabond A130 BLUE 0 01 40 N A Torque Tooling Refernce 2 Nm Torque wrench 50 CLS3E0048F Bracket Intercooler Mounting LHS 1 60 A912E7033V Sealant Permabond A130 BLUE 0 01 70 N A Torque Tooling Refernce 10Nm Torque wrench 70 N A Torque Tooling Refernce 2 Nm Torque wrench Page 28 of 39 ALS3T0008F SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY INTERCOOLER ISOLATION BUSHES 10 Collect required parts for operation from lineside storage position 20 Fit 2 isolation bushes to the RHS intercooler mounting bracket Secure using 2 off spring washers and 2 nuts 30 Tighten fixings to secure bushes to RHS intercooler mounting bracket Sor CIF 7 40 Fit remaining 2 isolation bushes to the LHS intercooler mounting bracket 50 Secure in the same way using 2 off sorung washers and 2 nuts 60 Tighten fixings that secure the LHS isolation bushes to the intercooler mounting bracket FIT ISOLATION BUSHES TO INTERCOOLER MOLNT NG BRACKETS AS SHON CAREPOINT QUALITY STANDARD SEQ PART NUMBER PART NUMBER DEED F C TORQUE TORQUE TOOUNG ALS3E6059F ISOLATOR BUSH d WASHER X 14 X 1 4MM 40 NUT NYLOC M8 P TYPE GR8 Zn 8 Page 29 of 39 ALSSTOO08F SU PERCHARGER PROCESS Version 1 S
15. HEET ACTIVITY FIT NEW DIP STICK AND TUBE UNTO FIXIS 8 THE THE SUPERCHSRGER THE 10 Collect component parts required for operation LIP STICK SUPPORT BRACKET RE Fit the original dipstick into the new dipstick tube and TEZHT EH AS SHOWA 20 ensure that the dipstick has click home fully into the tube Fit new O ring onto the end of the dipstick tube 7 EL WD AT CL 9 LIF TS T po enuring that the ring is seated correctly Push fit the dipstick tube assembly into hole Icoation 40 on the sumo of the engine enursing that the O ring stays correctly seated during fitting operation 50 Undo the fixing on the side of the supercharger 60 Place bolt through the dip stick support bracket trhen re fit back into removed location 70 Torque tighen fixin to specified torque Green paint mark the head of each fixing once ee correct torque has been achieved ENSURE THAT RINGIS CLATLED CORRECTLY ICH INSERTING THE DIPSTICK TUBE INTO THE BASE THE EH CAREPOINT QUALITY STANDARD 30 Ensure that O ring is fitted correctly onto dipstick tube L SEQ PARTNUMBER PART PART NUMBER PART DESCRIPTION E PAREDESGRIPTIOM S J TORQUE TORQUE Po Torque Tooling Refernce wrench Ring Dipstick Tube 1 20 CLS3E0051F Dipstick Tube 1 Page 30 of 39 ALSSTOO08F SU PERCHARGER PROCESS V
16. INN ALS3E0049F Sealing Bellows Intercooler To Duct ALS3E0052K Duct Hardtop To Bellows ALS3E0053F Duct Bellows To Intercooler BLS3E0050F RETAINING CLAMP BELLOWS ee Page 33 of 39 ALS SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY INTERCOOLER ANCILLARIES 10 Fit the map sensor to the intercooler using M6 x 16 bolt ensuring rubber seal on MAP sensor 15 intact Fit intercooler positioning on top of the 4 Isolation Bushesand secure with the remaining components of the 4 off isolation bush kits i e 4off plain nuts and 4off sprung washer lt gt 7 P 2 Map Sensor 20 30 Push fit the black Samco Hose 2 1 2 ID 60mm onto 1 the outlet of the outlet manifold port 2 the intercooler inlet 3 the intercooler outlet and 4 the inlet manifold inlet Fit intercooler left hand pipe and right hand pipe to either side pushing into the 40 previously position black Samco Hose 2 1 2 ID 60mm There should be approximate 3mm gap between the two mating surfaces Slide 2 hose clips onto each hose before fitting the pipes 50 Secure with two hose clamps at each end of the Samco 2 1 2 ID hose Ensure hose clamp heads are positioned as detailed above 60 Apply double sided tape around the duct edges and fit the bellows then apply the band clamps 70 80 zz PART NUMBER PARTDESCRIPTION jJ Ed
17. ITY RESBIT BREATHER AGIS EFE CE VER Ee VR HER dE 25 ACTIVITY HARNESS WIRING ROUTING A CONNECTORS csini E aN 26 ACTIVITY ALTERNA LOR ELECTRICAL CONNEC TOR va CE Hei vae MEME 27 NE R 8 6B saa oases RIA 28 ACTIVITY INTERCOOLER ISOLATION BUSHES vicscssaccoscasedessccssccsacasccscocasacsasnccacscaessdstscaascaccanctectnasesuatancesdszevsacccesesesucasteasadssssastessaedsaedsicasataotersecsoacasuedsncasacusnenacssueesaddaaneseatsanasiaccocasastedecsenteasesis taveascacstsatuacsasasucesics 29 ACTIVITY FET NEW DEP STICK AND TUDE a S 30 ANCE R orc E 31 ACTIVITY INTERCOOLER DUCTING AEEA
18. OINT QUALITY STANDARD E xii cg PART NUMBER PARTDESCRIPHON p AR DESCRIP TON GO EC TORQUE 1 TORQUE Torque Tooling Reference Hose Pliers Page 9 of 39 P N ALS3TOO08F PROCESS Version 1 SUPERCHARGER SHEET xi lt r 2 0 n 4 E k i 1 oy 4 gt ls one IDCM 10 Remove 2 studs that situated in the uet REMOVE REMAINING STUD FROM ENGINE ee _ fixing locations for the inlet manifold Once ALS a Hn ondes del removed discard fixings NR o c UN 20 Collect M8 stud and fit into centre location the engine 30 Torque tighten fixing to specified torque 40 Green paint mark head of fixing once correct torque has been achieved M Ell FIT HE STUD INCENTRE LOCATION AS HIGHLIGHTED E ut 5 CAREPOINT QUALITY STANDARD E Wii 53 PART NUMBER PARTDESCRIPTION E PARTBESEBIPTION p GE EC TORQUE TORQUE 111 60815 8 Stud wrench u N a Torque Tooling Reference 10Nm Torque wrench Page 10 of 39 ALSSTOO08F SU PERCHARGER PROCESS zx Wersion i SHEET ACTIVITY BREATHER MOUNT 8 HOSE 10 Remove lower section of breather hose with hose clamp pliers that is attached to the breather mount housing Place hose aside with spring clamps 20 Undo the 3 fixings that secures the breather mount housing to
19. R 10 On supercharger remove nose nut and place aside 20 Start the pulley installation by identifying the side of the pulley with the greater offset or longer neck This is the side that will go towards the supercharger Align the keyway in the pulley bore with the key on the input shaft and place the pulley on the shaft 30 Align the keyway in the pulley bore with the key on the input shaft 40 Fit the pulley onto the shaft keeping the ley and key way aligned 50 Fit the previously removed nut fit onto supercharger shaft to secure the pulley in postion with a strap wrench 60 Torque tighen the retaining nut that secures the pulley to specified torque 70 Green paint mark the head of each fixing once correct torque has been achieved fs CAREPOINT QUALITY STANDARD 20 Do not use hammer or mallet to install or remove the pulley onto the shaft as this will damage the supercharger 50 Be careful not to damage the supercharger pulley while fitting the strap wrench PART NUMBER PART DESCRIPTION TORQUE TOOLING 20 BLS3E6042J Pulley 1 50 Torque Tooling Refernce Strap wrench 70 Torque Tooling Refernce 61Nm Torque wrench Page 23 of 39 ALSSTOO08F SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY FIT AUXILIARY V BELT FIT Y BELT TO ENGINE AS SHOWA EY THE VISUAL BELOW ENSURE THAT THE BELT iS SEATED 10 Obtain required parts for operation CORRECTLY 20 Fit V belt tensioner com
20. Rear clamshell including passenger seat under heen NC uU tray wheel and liners E 20 Remove Exhaust Cat pipe and remove rear engine mount heat shield plus exhaust manifold stay 30 Remove EVAP canister bracket and pipes from rear bulkhead and bobbins 40 Hemove Air box 50 Undo the 4 fixings that secure the coil pack to the engine 60 Remove coil packs and place to one side with fixings for re fitment 70 Using spark plug removal tool undo and remove all 4 spark plugs Once removed discard spark plugs 80 Collect new uprated spark plugs 90 Using spark plug tool fit 4 new spark plugs Tighten spark plugs so that they are hand tight 100 Using specified torque wrench torque tighten sparks plugs to required torque 120 Re fit coil packs as removed ensuring that they have clicked home Torque tighten retaining bolts on coil packs to ai specified torque O 130 Green paint mark head of each fixing ENSURE THAT ALL 4 Fd GS HAVE CLICKED HOME 1 140 Remove auxiliary drive belt BEFORE THE AXING BEEN TORQUE TIGHTENED diii zz r ia idi a F 3 E cU NET E p qm LECT a RC EU E 2 CAREPOINT QUALITY STANDARD 70 When re fitting the coil packs ensure that they have clicked home over the spark plugs SEQ PART NUMBER PART NUMBER DESCRIPTION PART DESCRIPTION LeTy EC TORQUE _ TORGUE TOULINN
21. URES ARE FOLLOWED AND PRECAUTIONS TAKEN ACTIVITY MATERIALS AREA PROCESS CAREPOINTS CLEAN Ee 3900 Either work area wipe only with Dampen paper with BETACLEAN 3900 wipe bond path amp then dry wipe EE mask BETACLEAN 3900 IMMEDIATELY with clean paper goggles CLEAN PROCESS VP04604 Trim amp final area wipe only with Dampen paper with BETAWIPE VP04604 wipe bond path amp then dry wipe Gloves mask 2 Betawipe VP04604 chassis glass etc IMMEDIATELY with clean paper goggles WARNING DO NOT ATTEMPT TO DO THIS MODIFICATION WITH THE ENGINE RUNNING OR WHEN THE ENGINE IS NECESSARY PRECAUTIONS TO GUARD AGAINST FIRE AND EXPLOSION RISK WHEN DEALING WITH FUEL AND FUEL VAPOUR LOTUS SPORT RECOMMEND RUNNING THE VEHICLE WITH THE ACCUMSUMP AND CLUTCH UPGRADE ENSURE THAT BRAKE UPGRADE IS FITTED READ THESE INSTRUCTIONS THOROUGHLY BEFORE COMMENCING WORK AND ENSURE ALL COMPONENTS ARE PRESENT IF IN ANY DOUBT CONSULT A LOTUS DEALER BEFORE UNDERTAKING THE WORK Page 2 of 39 P N ALS3TOOO8F SU PERCHARGER PROCESS LE Version 1 SHEET eR ON SPARK PLUG reac M M 4 PT TE AE TUT ERE SID a 5 ACTIVITY THROTTLE BODY amp CABLE AL PERNA
22. and fit new decals to ECM Note earlier cars will require a new ECM sold separately 60 Attach engine hook to engine and support the engine weight on hoist 70 Undo 4 fixings for RHS engine hydro mount Remove engine mount and place aside Note engine mount may have a surcharge applicable 80 Collect modified engine mount Fit engine mount to engine with previously removed fixings Apply locite 5910 to upper left fixing and torque tighten fixings using specified torque wrench Green paint mark head of fixing bolts 4 Fi gt THAT SECUPES THE Water PURE PULLEY THE ENGINE SLACKEN OFF REMAINING BOLTS So THAT THEY _ ARF VERY OSF AIT OO WoT RRR CAREPOINT QUALITY STANDARD eee PART ML PART DESCRIPTION LS PART DESCRIPTION EC TORQUE _ NS TOOLINN S Torque Tooling Reference M Loctite 5910 Page 8 of 39 P N ALS3TOO08F 2 97 gt Version 1 SUPERCHARGER PROCESS SHEET T ri Lem SEQ L ACTIVITY CAM COVER BREATHER COVER BREATHER REMOVE THE 2 FIXINGS FOR UPPER NEL BREATHER PIPE 45 SHOWN B P m 10 Undo 2 fixings that secure the breather pipe to the cam cover Place fixings aside for re fitment 20 Using hose clamp pliers release clip that secures the upper breather pipe to the lower breather hose 30 Hemove the cam cover breather hose and discard RELEASE LOWER BREATHER PIPE CLAMP BREATHER HOSE CAREP
23. aseal 1701 10 ALS3E0052K Hardtop to Bellows Duct Page 32 of 39 P N ALS3TOO08F PROCESS Version 1 SU PERCHARGER SHEET Taking the Hardtop to Bellows Duct fettle the duct and or clamshell to ensure correct fitting and alignment between the intercooler duct and hardtop duct score the surface with a knife and scotch brite to prepare the surface for bonding Dry fit the 10 duct until the aperture on the duct is flush with the aperture on the roof Ensure that the upper front surface of duct is flush with inner roof skin This will allow maximum bonding area The duct should almost click into place when in correct position This may take several attempts to correctly position Using Betaprime 5404 prime the inner surface of the clamshell fitted area only and the duct Then using Betamate 1701 bond the duct in place and secure with masking tape 30 Will require 24 hrs to go off Set aside Ensure aligned with the Intercooler duct and tape into position 40 When complete fit sealing bellows to intercooler and roof ducting FETTLE THESE AREAS IF APPLICABLE SCORE AND GLUE ALL MARKED AREAS PLEASE NOTE IT MAY BE 20 NECESSARY TO ADJUST THE HINGES SO THAT THEY MISS THE SIDE OF THE DUCT AND LOWER SURFACES INDICATED BY DOTTED LINE N CAREPOINT QUALITY STANDARD 30 PART NUMBER DESCRIPTION wu 0 0 TORQUEq TORGUE TOOL
24. ated Both upper and lower keeper bars should be checked to see that they are correctly position The four terminals Shown should be clearly visible and aligned Keeper bar ends should not be flush with ECU connector housing Visible Indications that the Keeper Bar is Incorrectly Located Both keeper bars have been pushed out of location away from the harness cable end The four terminals shown above are no longer visible and not aligned Keeper bar ends are flush with ECU connector housing MGE Keeper bar ends flush with ECU 4 terminals not longer connector housing Incorrect visible Page 13 of 39 ALSSTOO08F SU PERCHARGER PROCESS SFP ORT Version 1 SHEET ACTIVITY RE FIT FUEL RAIL 10 Obtain Supercharged Engine harness storage position ready for fitment to engine 20 20 Locate harness to engine so portion of harness with Injector breakouts is positioned in channel between inlet manifold and cylinder head with coil pack breakout of harness at gearbox end of cylinder head 30 Manoeuvre harness so that breakouts for injectors are facing uppermost and are in line with injector ports in cylinder head 40 Obtain fuel rail removed earlier 50 Remove injectors from fuel rail and place into injector ports ensuring that seals are seated correctly 60 fuel rail onto top of injectors ensuring that the injectors are seated correctly into the fuel rail
25. d fixing required for operation and place on work surface ALSSTOO08F SU PERCHARGER PROCESS SOF TF Version 1 SHEET ELE ACTIVITY REFIT ALTERNATOR NOSE BRACKET 10 Collect parts required for operation FIXING TO FRONT ALTERNATOR B i ai FIRING POINT WITH 20 Re fit the alternator but fitting the lower fixng only Fixing to be used MOUNT FLANGE 135mm SPACER is what was previously removed Tighten the fixing hand tight onl HEAD BOLT WITH BETWEEN 119 9 9 30 Fit nose bracket to the front upper engine mount using a M10 x 50 flange head bolt and a M10 flange nut Leave hand tight 40 Fit the other end of the nose bracket to the upper alternator mount using the 13 5mm spacer and a M8 x 55 flange head bolt Leave hand tight Tighten the lower alternator fixing to specified torque and loctite 50 Torque tighten the front upper fixing from nose bracket to engine mount This sets the position of the nose bracket 60 Remove the fixing that secures the upper alternator to the nose bracket Swing the alternator out of the way The nose bracket should not move 70 Green paint mark the head of each fixing once correct torque has been achieved MIONUT AND SPACER ALTERHATOR AND NASE BRACKET 7 H P ge LOWER ALTERNATCR FIXING D B 1 E L NH E ZW E DE 30 Ensure that O ring is fitted correctly onto dipstick tube PART NUM
26. e Breather Pipe not yet fully ORIGINALLY C FRC POSTION 3 fitted and the Inlet Manifold Follow tight line down beside the FOR POSITION 3 IS REUSED BUT Cylinder Head and Block to the back of the Alternator ob ERY Abd PATIO dec n id is MEIN hts LE RART NUMETRI JPABFDESCBIPTION JILOTY C EG eee S BLS3E6042J Assy Supercharger Inlet Manifold 1 o ALSSE6026F M8x30 Flange head bolt 3 20 120 63255 40 bolt 1 20 53 6327 flange head unit 1 30 120 63425 Inlet Manifold Gasket 1 20 Sealant Permanbond A130 BLUE 0 01 70 N a Torque Tooling Reference 27Nm Torque 90 N a Torque Tooling Reference 10Nm Torque Page 12 of 39 P N 153 0008 SU PERCHARGER PROCESS Version 1 SHEET Sor CFF 7 Technical Bulletin CUP240 02 Class 3 ENGINE HARNESS ALS3M0011K INFORMATION BULLETIN January 2006 Lotus Sport Performance ENGINE HARNESS ALS3MO001 1k fitting recommendations It is essential that up most care be taken when handling and fitting the engine harness ALS3M0011K Electrical connectors clips and terminals are delicate in nature and can be easily damaged Please note the location of the keeper bars white plastic terminal housing on the ECU connector indicated below Please check the harness and all connectors before fitting Visible Indications that Keeper Bar is Correctly Loc
27. eated correctly into groove of outlet manifold 40 Ensure that the ring stays correctly seated into groove when mating surfaces Ensure that permabond is applied to fixing 2 the full length of the thread 80 Ensure that the ring is correctly seated into groove CSQ j PART NUMBER PART NUMBER PART DESCRIPTION QTY SEORQUE TORGUE TOOLINN BLS3E6042J Assy Supercharger E Betaclean 3900 20 ALS3E0029F Supercharger Outlet Manifold 1 30 ALSSE6069F ring Supercharger outlet 1 60 N A Torque Tooling reference 25Nm Torque wrench 70 Betaclean 3900 0 05 80 ALSSE6069F o ring Swan Neck 1 Page 16 of 39 pene P N ALSSTOO08F PROCESS 43 F Pg d 7 Ve rsion 1 S U P E H SH E ET ACTIVITY SUB ASSEMBLY SUPERCHARGER SWAN NECK 10 Collect required parts 20 Sub assemble the two brackets to the 2 longer flange head bolts 30 Fit the outlet manifold port to the supercharger outlet manifold using 2 off M8 x 25 and 2 off M8 230 flange head bolts 40 Torque tighten fixings to specified torque Green paint mark the head of each fixing once correct torque has 4 E CLI CFF FIR TREE CONNECTORS I BK AC AS SHOU ALSO SHOVING ORIENTATION OF THE BRACKETS _
28. ersion 1 SHEET CONNECTCE FROW THE CRANK SENSOR WACH AT ALHS 10 Obtain Harness at Water outlet on front of engine block SLE WALL OF THE APSTICX Obtain Alternator breakout from main harness and engage LL en into plug on front of alternator v P 39 Obtain AC Compressor breakout from main harness and ITE E REN engage into plug on front of AC compressor ERNATOR AS 40 Obtain plug end of crank sensor removed from dipstick tube in op 50 Engage connector on end of crank sensor breakout from SOMME T PLUG 1 HTo THE AC main harness into plug from crank sensor COMPRESSOR AS SHOWN Obtain water temperature sensor breakout from main 60 harness and engage into plug on water temperature sensor on front of engine block Obtain final two breakouts and route across front of 9 engine block towards gearbox Engage oil temp sensor breakout into sensor on front of 80 i engine block directly above sandwich plate 90 Engage final breakout from engine harness into connector on RHS of starter motor 100 Ensure all connectors are fully engaged and clicked home pem Using tie wrap Secure harness to main water outlet on ET AIR WATER 110 TEMPESATLEE front of engine block SEW EREAEOLIT 120 Using Side Cutters Trim tail of tie wrap and discard TH 2 BNO PIG INTO SENSOR o A TER DROAK OUT PLJG
29. face Using CLEAN PROCESS 1 clean area on both mating surfaces of the outlet FRY 7 20 HIGHLIGHTED AREA S SHOWING manifold and the supercharger OF THE AXINGS Cut o ring to perimeter length for the face between the supercharger and THAT SECURE THE OUTLET 30 supercharger outlet manifold Make sure that ends of the ring are parallel apply MANIFOLD TO THE SUPERCHARGER ASSEMELY primer to the ends and super glue to Join 40 Fit outlet manifold to the supercharger using 6 off M8 x 25 fixings Apply permabond to the threads of fixings With fixing 2 apply permabond the full length of the thread The outlet manifold should be fitted with he port face facing away from the 50 ns supercharger nose i e towards the front of the vehicle when in situ 60 Torque tightens fixings in correct sequence and to specified torque Green paint mark the head of each fixing once torque has been achieved Using CLEAN PROCESS 1 clean surface of the outlet manifold port that mates with i the supercharger outlet port a Cut o ring to perimeter length for the face between the swan neck and supercharger ene Tun LE 80 outlet manifold Make sure that ends of the ring are parallel apply primer to the GROOVE OM BOTH MATING ee eee ae ends and super glue to join and fit SURFACES A5 SHOWN BY fm VISUAL CAREPOINT QUALITY STANDARD 30 Ensure that ring is s
30. g alternator away from engine so that it is out of the way 70 Once loose discard fixings and also stabiliser bracket 80 Remove alternator upper fixings foam from loam and 8mm stud LPI REMOVE APRS THAT SECLISES THE THROTTLE THE INLET FOLO AS HoHLII OPTED Note Picture indicates electronic throttle kits supplied to third parties will have mechanical throttle Process identical apart from cab e NOTE ALTERNATOR SWUNG OUTWARDS CAREPOINT QUALITY STANDARD eae sd PART PAET NUMEER Pen DE ORP TION EC TORQUE TORQUE TOOLING Torque Tooling Refernce meane a clamp pliers Page 6 of 39 P N 153 0008 SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY INLET MANIFOLD Undo the fixing that secures the upper section of the 10 dipstick tube to the manifold Remove fixing and place aside for re fitment Undo the 3 fixings on the RHS of the inlet manifold to remove the triangular bracket Undo the 5 fixings that secure the upper main section of the inlet manifold to head and place fixings aside Undo remaining lower fixing that secures the inlet 40 manifold to the head Remove and place aside for re 20 30 fitment UNDO 3 FLXINGS ON RHS 50 Remove manifold from engine and discard IMLE 60 Remove gasket and discard 70 Using masking tape cover the ports to the engine to prevent dirt dust etc bei
31. h for the face between the Supercharger and supercharger inlet manifold Make sure that ends of the o ring are parallel apply primer to the ends and super glue to join 40 Fit o ring into groove on the supercharger inlet manifold ensuring that the o ring is seated correctly into the groove 50 Fit the supercharger inlet manifold to the rear of the supercharger using 2 off M8 x 30 x 1 25 Flange head bolts and 1 off nut for stud fixing Hee 60 Leave the lower left bolt fixing out This is to be fitted later ITSELF FIT THE gt 55 FIXING TO THE LOWE Torque tighen 3 fixings to specified torque LEFT LOCATION AS SHON BY THE 4ECVE 70 Green paint mark the head of each fixing once correct torque has VISUAL been achieved 80 Fit 7mm supercharger nose spacer to supercharger nose ensuring that it is pressed until it firmly butts up against the back plate 30 Ensure that o ring is seated correctly into groove 50 Do not tighten fixing PARTNUMBER PART DESCRIPTION ET 27 70700 CLS3E0031J Assy Supercharger In Swan Neck ALS3E6069F O Ring Outlet Port 20 ALS3E6072F BOLT M8 X 1 25 X 55 HEX FLANGE 1 50 53 6062 BOLT M8 X 30mm FLG HD 2 70 Torque Tooling Refernce Torque wrench 60 ALS3E0063F 1 Page 19 of 39 7m Spacer Supercharer Nose SUPERCHARGER PROCESS SHEET ACTIVITY SUB ASSEMBLY SUPERCHARGER INLET MANIFOLD 10Nm Collect all parts an
32. hten 30 Torque tighten the pinch bolt on the end of the nose bracket to specified torque ensuring that surpercharger is still hard against the nose bracket 40 Remove the bolts retaining the clutch slave cylinder but hold the slave cylinder in position remove clamp bracket and clip Discard bolts clamp bracket and clip 50 Loosely fit the supercharger support strut at the remaining hole on the swan neck manifold using M8 x 55 bolt and permabond A130 60 Using permabond A130 bolt the lower into position using the new longer M8 x 25 bolts Torque tighten the supercharger support strut bolts to specified torque 70 Carefully tighten the 2 off M10 x 50 flange head bolts evenly so that the 2 sliding bushes pull in together and clamp the supercharger equally 80 Torque tighten the M10 x 50 flange head bolts to specified torque 90 Green paint mark the head of each fixing once correct torque has been achieved 30 Ensure that supercharger is hard against the nose bracket PARTNUMBER E PAHFDESCRIBHON _ Torque Tooling Refernce 25Nm Torque wrench E BLS3E0068F Stay Mounting Supercharger 1 50 120 63245 Bolt M8 25 Stay Mtg 2 60 Sealant Permabond A130 BLUE 0 01 90 Torque Tooling Refernce 25Nm Torque wrench Page 22 of 39 P N 153 0008 SU PERCHARGER PROCESS Version 1 SHEET 70 _ Torque Tooling Refernce 50 Torque wrench ACTIVITY PULLEY SUPERCHARGE
33. ling Reference 10Nm Hose clamp pliers Page 11 of 39 ALSSTOO08F SU PERCHARGER PROCESS ZO gt Version 1 SHEET ae POINTS 2 ANDA ARE REFITTEPIN THE ACTIVITY FIT NEW INLET MANIFOLD ORIGINA amp THEY ERP 2 e 10 Collect new inlet manifold 20 Collect all relative fixings required for operation and apply permabond A130 to threads of 3 off M8x30 Flange head bolts also to flange head unit 30 Fit new gasket and inlet manifold to engine using the fixings specified 40 Using 3 off M8X30 flange head bolts fit into 2 upper fixings locations and lower left fixing 50 Fit lange head nut to lower centre location onto stud 60 Do not apply permanbond to the M8x40 flange head bolts as this has to be left loose Do not tighten indication Hand fit into lower right fixing position to aid alignment of the inlet manifold 70 Torque tighten fixings to specified torque 80 Once fixings have been torque tightened remove the M8x40 flange head bolt and place aside for refitment B indication 90 Using specified torque wrench torque tighten the single fixing that secures the VVT valve to the head 100 Green paint mark the head of each fixing once correct torque has been achieved 110 Fit new engine wiring harness to engine This follows the same routing with the exception of around the inlet area for the Main Inlet Manifold FIXING FOR POSITIONS ISR EUSED B m Here the loom needs to fit between th
34. necessary to modify the ECM backing plate to accommodate the supercharger unit Bend In Metal 10 Remove the ECM backing plate from the vehicle 20 Mark out an area starting from the upper right hand side of the backing plate with dimensions 80mm from the right and 150 mm from the right hand top corner Cut this section out as shown below and keep intact as this will be used later 30 Using the section that has been removed 40 Drill an two holes through this small angled section 10mm in from the left and 10mm up from the bottom at 5mm and 10mm up respectively as shown 50 Bolt this angled section as shown 60 For the 2 fuse relay bolt this to the further most inboard part of the ECM plate 70 Refit the ECM plate and all ancillaries ECM confirm correct calibration in ECM as per the reverse order as was removed 15 4 10 30 40mm 25 4 5b 15 40mm Fuse Box using bent connector CAREPOINT QUALITY STANDARD 70 Check that fuses relays are secure and that no fouling or interference is visible at any point in the installation Check ECM contains the correct calibration 70 See technical bulletin Cup240 002 at end of this document PART NUMBER PART DESCRIPTION TORQUE TOOLING 50 20 20 20 Page 15 of 39 ALS3T0008F SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY SUB ASSEMBLY SUPERCHARGER OUTLET 10 Collect parts required for operation place on a suitable clean and tidy work sur
35. ng inhaled 80 Remove the foam padding situated below the inlet manifold FISKING THAT SUPPCRTS THE UPPER OP TUBE AS CAREPOINT QUALITY STANDARD PART NUMBER PART DESCRIPTION TORQUE TOOLING Page 7 of 39 ALSSTOO08F S U p E RCH ARG E R jn Version 1 lt gt 7 TERG LTAT OHS OF THE HOURT PEMOVE FIZINGS FIT ENGINE Loe ATIC ACTIVITY RHS Engine Mount 10 Remove the 4 fixings that secure the upper exhaust manifold and place fixings and heat shield to one side for UPPER CHINE re fitment ne un TO 20 Remove the 2 outside nuts that secure the exhaust manifold aio to the engine and place to one side Slacken off the remaining 3 bolts so that they are very loose but do not remove 30 Undo fixing that secures the bracket for the ERG rail Remove fixing and place aside for re fitment 40 Using a small screwdriver lock off the water pump pulley using one of the 4 small holes on the face of the pulley Undo and remove 4 fixings that retain the pulley to SA E pump shaft Place 4 fixings and pulley to one side for re HM THE TAI CH EXHAUST a fitment RR SEI Zu a 50 Remove the the engine wiring harness ecm and backing ml PEE BM ki plate from the vehicle If applicable Flash ECM
36. nue SUPERCHARGER Sem Sor CIF 7 TO SS SFP OOF 7 IN Lotus Sport Fitting Instructions Supercharged Toyota 2ZZ GE Engines Application Specific in S2 Exige Supercharger Kit ALS3E0073UJ is for VIN numbers from 82384 Supercharger Kit ALS3E0076uJ is for VIN numbers upto and including 82384 kit to include the ECU Difficulty m m m of Page of 39 ALS3T0008F SU PERCHARGER PROCESS Version 1 SHEET Sor CIF 7 TOOLS REQUIRED LOTUS SERVICE MANUAL A120T03274J TOYOTA SERVICE MANUAL RM733E TOYOTA SERVICE MANUAL RM929E VEHICLE SUPPORT RAMP OIL DRAIN CAN RATCHETS SPANNERS ASSORTED ALLEN KEYS ASSORTED PHILLIPS HEAD SCREWDRIVER FLAT BLADED SCREWDRIVER SIDE CUTTERS BOILING WATER TO SOFTEN HOSE ENDS SOCKETS ASSORTED LOCTITE 120 BETASEAL BETAPRIME STUD EXTRACTOR SET CRAFT KNIFE BETASEAL 1701 SUITABLE GUN FOR APPLING BETASEAL CIRCLIP PLIERS MASKING TAPE CLEAN WORKING BENCH AND AREA TORQUE WRENCH EXTENSION BARS COTTON BUDS FOR PRIMER APPLICATION PAINT PEN HACKSAW OR SUITABLE CUTTING TOOL MALLETS HAVOLINE XLC COOLANT WATER 50 MIX STRAP WRENCH INSTRUCTIONS NOTE 1 THE SUPERCHARGER WILL BE FITTED TO THE ENGINE WHILST IN SITU NOTE 2 ALL BOLTS SHOULD BE TORQUED CORRECTLY SEE LOTUS SERVICE MANUAL FOR STANDARD PART OR TORQUE REFERENCE NOTE 3 ALL BOLTS TORQUED SHOULD BE PAINT MARKED NOTE 4 ENSURE ALL NESSECARY SAFETY PRODEC
37. of Em ux i cylinder head 10 20 i PD oc x j There will be two remaining breakouts at alternator end ENGAGE BREAKOUT CAMSHAFT gt oe 70 of fuel rail These are for Intercooler MAP sensor and POSITION SENSOR OM FRONTOF CY INDER d Pu a S EVAP canister These will be connected later CAREPOINT QUALITY STANDARD PART NUMBER PART DESCRIPTION TORQUE TOOLING Page 26 of 39 P N 153 0008 SU PERCHARGER PROCESS Version 1 SHEET ACTIVITY ALTERNATOR ELECTRICAL CONNECTOR Connect branch from the harness to the alternator Make sure that the plug has clicked home CAREPOINT QUALITY STANDARD 10 Ensure that the plug has clicked home when connecting harness to alternator PART NUMBER PART DESCRIPTION TORQUE TOOLING Page 27 of 39 P N ALS3TOO08F PROCESS Version 1 SU PERCHARGER SHEET 10 Collect required components for operation 20 Fit RHS intercooler bracket to the fixing points on the inlet manifold and cam cover 30 Secure bracket using 2 off M8 x 25 flange head bolts with permabond A130 40 Torque tighen 2 intercooler mount brackets to specified torque 50 Fit the LHS intercooler mount bracket to the inlet manifold and cam cover Secure bracket to engine using 1 off M8 x 40 and 1 off M6 x 16 bolt with permabond A130 70 Torque tighen 2 fixings to specified torque 80 Green paint mark the head of each fixing once correct torque has been achieved
38. prssion tool to the belt tensioner 30 Collect V belt and fit to engine 40 Once belt is fitted release V belt tensioner compression tool to allow V belt to correct tension 50 NON AIR CONDITIONED VEHICLES An additional Bracket for cars that do not have air conditioning is required Before fitting the Auxiallary Drive Belt Bolt the Additional Bracket using the 3x M8 x 16 Bolts to the same holes as used to mount the Air Conditioning Unit Then bolt the Pulley to the Bracket using the long bolt and Lock Nut supplied Loctite and Torque to 27Nm MTY BELT TEHS5IOHER COMPRESSION TOOL TO TENSIONER AS SHOWN ALLOW BELT FITMENT CAREPOINT QUALITY STANDARD 30 Ensure that the V belt is fitted as per visual and that it is seated correctly before releaseing tensioner E PART NUMBER PART DESCHIETION Le TORQUE J S Torque Tooling Refernce V belt tensioned compression tool E MEI Belt V Rated A C 1 50 120 64035 Pulley 1 50 A120E6404S Bolt 1 50 120 64805 Nut 1 50 BLS3E0064F Mounting Brkt Pulley Non Aircon 1 50 A075W 1036Z Bolt M8 X 16 3 Page 24 of 39 SU PERCHARGER PROCESS SHEET ACTIVITY RE FIT BREATHER PIPES 10 Re connect brather pipes that were previously disconnected from the side of the head on the engine 20 Push fit both hoses back onto location necks 30 Using hose clamps pliers re fit the hose clamps that secure the hoses
39. sure that each aligns and is flush with the ABS ducting bonding behind 40 Seal any intake area edges to prevent air loss Page 38 of 39 ERROR undefined OFFENDING COMMAND STACK
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