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Lotus Evora. Manual - part 8

Lotus Service Notes

Section BV

BV.4 - FRONT CLAMSHELL

The front clamshell comprises a composite moulding forming the front upper bodywork between the base

of the windscreen and the front bumper. Incorporated into the panel are apertures for the radiator air outlet

grilles, and a recess for the hydraulic fluid and windscreen washer reservoirs. The panel is secured by threaded

fasteners for ease of access to the HVAC and engine cooling radiator, and to allow economical panel repair or

replacement. The panel is secured to the front subframe via mounting brackets, and to the front bumper and

'A' panels, with provision being made for height and shutline adjustment.

Front clamshell removal/replacement

The clamshell with front access panel may be removed whilst leaving the front bumper in position:

1. Remove both front wheels and wheelarch liners.

2. Open the reservoir access hatch, remove the three screws securing the latch, and disconnect the release

cable. Feed the cable through the clamshell grommet. Release the two fixings securing the hydraulic

fluid reservoir to the clamshell, and the two screws securing the washer reservoir filler neck. Release the

washer tube and harness connector from the washer jet.

3. From within each wheelarch, disconnect the headlamp harness and headlamp washer tubing. Release

the two fixings securing the headlamp front mounting bracket to the subframe, and the two fixings securing

the headlamp rear bracket to the bumper support bracket. Withdraw the headlamp.

4. From within the front of each wheelarch, release the three fixings securing the clamshell to the top edge

of the bumper.

5. From within the back of each wheelarch, release the two fixings securing the clamshell to the top of the

'A' panel, and the single screw to the chassis bracket. Disconnect the side repeater lamp.

6. From the headlamp apertures, release the two nuts at each side, securing the front edge of the clamshell

to the mounting rail.

7. Prise out the nose badge taking suitable precautions to avoid paint damage. From the access hole re-

vealed, remove the single fixing securing the clam to the mounting rail.

8. Carefully lift the clamshell from the car and place on a protected surface.

9. Refit in reverse order to removal, noting that all fixing points incorporate provision for adjustment of panel

height and alignment via slotted holes or shim washers. The height of the clamshell front fixing rail is

adjustable against the subframe at the three slotted fixing points on the rear face, accessible via the head-

lamp apertures. Clamshell adjustments must be completed before the headlamps are fitted and adjusted

to seal correctly against the clamshell apertures.

10. Check headlamp beam alignment.

BV.5 - FRONT BuMPER

The front bumper may be removed with the clamshell in place, but the headlamps must be removed to

provide access to the upper fixings.

1. Remove both front wheels and wheelarch liners. At each side, disconnect the headlamp harness and

headlamp washer tubing. Release the two fixings securing the headlamp front mounting bracket to the

subframe, and the two fixings securing the headlamp rear bracket to the bumper support bracket. With-

draw the headlamp.

Lotus Service Notes

Section BV

2. From each headlamp aperture, release the three fixings clamping the bumper top flange to the clamshell

and to the support bracket.

3. From each headlamp aperture, slacken the two nuts securing the front edge of the clamshell and bumper

top flange to the support rail. Prise out the nose badge taking suitable precautions to protect the surround-

ing paintwork, and slacken the single nut securing the centre of the clamshell and bumper.

4. From beneath the car, release the fixings securing the front undertray to the lower edge of the bumper,

and the two screws securing each lower rear corner of the bumper to the support bracket.

5. Withdraw the bumper.

6. Ensure the bumper foam is fitted to the subframe before replacing the bumper in reverse order to removal,

inserting the top flange between the clamshell and support rail.

BV.6 - REAR CLAMSHELL

The rear clamshell comprises the principal body moulding aft of the doors and includes the integral boot

box. The separate rear bumper panel is screw fixed to the rear face of the clamshell. The front of the clamshell

is secured to the body side mouldings and the back edge of the roof panel, with the back end supported via

the boot floor to the rear subframe. The tailgate hinges reach beneath the top edge of the clamshell to fix onto

the rear bulkhead, such that the tailgate needs to be removed before the clamshell may be released. The rear

bumper may remain fitted to the clamshell. Two people are required to lift the clamshell from the vehicle, and

sufficient space provided to store the panel without paint damage.

Front bumper

Adjustable support rail

Bumper/headlamp

support bracket

Diffuser spat

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Lotus Service Notes

Section BV

Rear clamshell removal/replacement

1. Tailgate: Remove the tailgate (see BV.2), both rear wheels, and wheelarch liners.

2. Ventilation panel: The engine bay outlet ventilation panel around the top edge of the tailgate aperture

needs to be removed to provide access the clamshell to roof fixings.

- From beneath the clamshell aperture, release the 2 fixings securing the vent panel to the roof rear flange,

and one at each side fixing to the body side panel.

- Draw the panel rearwards and lift to release from the keyhole slot at each front corner.

3. From the access provided by op. 2, remove the two nuts securing the clam to the roof rear flange, and the

single nut to each body side panel.

4. Battery: Remove the battery cover, battery and tray, and feed the two battery cables out through the clam-

shell grommets.

5. Boot box: From inside the boot, release the 8 fixings securing the boot floor to the subframe, and the 4

fixings in the boot front wall securing the heatshield. Release the single screw securing the header tank

bracket to the boot wall.

6. Wheelarch: From within the front of each rear wheelarch, release the fixing securing the clamshell to the

body side top flange. Reach further forward with an M10 socket and short ratchet handle to release the

similar fixing at the front of this flange.

7. Remove the fuel cap and pull the grommet over the filler neck. Re-seal the neck. unplug the flap release

solenoid connection.

8. At the back of each wheelarch, release the two fixings securing the clamshell to the subframe bracket,

and the 2 fixings to the diffuser panel.

Boot floor to subframe

Clam to roof rear flange

Acess from interior

Clam to body side

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Lotus Service Notes

Section BV

9. At each side, release the front seat belt upper anchorage from the 'B' post, and pull off the 'B' post top

trim. Pull the weatherstrip seal off the body vertical flange at the rear of the door aperture. Pull the rear

quarter trim panel away at its top edge to release the two spring fasteners beneath the quarter window.

This should allow sufficient access to the single M8 headed screw securing the topshell to the body side

just below the front end of the rear quarter window.

10. unplug the rear harness at the RH side of the boot and feed the harness through the panel. unplug the

cable to the reversing camera and withdraw the cable through the clamshell. At the left hand side of the

boot, disconnect the parking sensor module and tyre pressure monitoring harnesses and feed through

the clamshell.

11. Carefully lift the clamshell from the body and lay aside on a protected surface. Note and retain any shim

washers or plates used at each fixing point.

12. Refit the clamshell in reverse order to removal, taking appropriate precautions to protect surfaces from

damage during the installation process. Refit any shim washers or plates noted on disassembly. Assess

shutlines and panel heights as early as possible and amend shim stacks as necessary.

BV.7 - REAR BuMPER

The rear bumper moulding is screw fixed to the rear face of the rear clamshell, and covers the impact foam

secured to the rear subframe. It also incorporates the rear transom panel, houses the licence plate lamps and

rear fog and reverse lamps, and mounts the diffuser finisher.

Rear bumper moulding

Single screw outboard

of tail lamp

Nuts in tailgate aperture

Accessed via grommet

hole in boot

Support bracket

to subframe

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Content .. 6 7 8 9 ..