Lotus Evora. Manual

Lotus Service Notes

Section BV

BODY FITTINGS

SECTION BV

Sub-Section Page

General Overview - 2

Reservoir Access Hatch BV.1 3

Tailgate BV.2 3

'A' Panels BV.3 4

Front Clamshell BV.4 5

Front Bumper BV.5 5

Rear Clamshell BV.6 6

Rear Bumper BV.7 8

Door Mirrors BV.8 9

Door Shell, Beam & Hinges BV.9 10

Door Weatherstrip Seals BV.10 11

Door Window, Guide Rails & Lift Mechanism BV.11 12

Door Latch Mechanism BV.12 14

Windscreen Removal/Replacement BV.13 15

Tailgate Glass BV.14 17

Cabin Rear Window BV.15 18

Rear Quarter Light Window BV.16 18

Lotus Service Notes

Section BV

Front clamshell

indscreen frame

Roof panel

Rear bulkhead

entilatio

n panel

Tailgate

Reservoir access hatch

Rear

spoiler

Front bumper

'A' panel

Door

Body side panel

Rear clamsh

ell

Rear bumper

Front subframe

Main chassis tub

Rear subfram

GENERAL

OVER

VIEW

Seat belt mount

ing frame

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Lotus Service Notes

Section BV

BV.1 - RESERVOIR ACCESS HATCH

The Lotus Evora is fitted with a front hinged,

composite, access hatch in the front body to

provide ready access to the brake/clutch mas-

ter cylinder reservoir and windscreen washer

reservoir filler neck. Incoming air to the interior

climate pollen filter is also routed through this

area from the high pressure zone at the base of

the windscreen.

To open the hatch, from the inboard side of

either footwell, press down the release lever; the

hatch may then be raised fully by hand.

Before closing, check that the reservoir caps

are secure, lower the lid, and press firmly over

the latch.

Access panel adjustment

The hinge stator is secured by two M6 nuts to a captive studplate on the clamshell, with sufficient hole

tolerance to allow some adjustment of panel height. Similarly, the hinge rotor is secured by 2 M6 nuts to a

studplate in the cover, with allowance made for adjustment of shutlines.

BV.2 - TAILGATE

The composite tailgate panel is hinged at its leading edge to the rear bulkhead, and uses a single latch

mounted centrally at its rear end. The latch is released by an electric solenoid activated by the transmitter key

fob, but note that unlatching is inhibited with the ignition switched on. An emergency release is provided in the

form of a mechanical cable from a handle concealed beneath the rear seat cushion (or carpet). Opening of the

tailgate is assisted by a pair of gas pressurised struts. The tailgate incorporates a heated window glass, and,

to the rear of the glass, an outlet grille for hot air from around the rearmost catalytic converter.

The extruded alloy hinge arms are bolted to the tailgate with two M8 screws and reach beneath the venti-

lation panel to the cabin rear bulkhead, to which the hinge stators are secured with two M8 screws. The steel

hinge pin is an interference fit into the stator, and supports two top hat synthetic bushes pressed into the bore

of the hinge rotor, with an 'E' clip used for retention. Oversize hinge fixing holes allow for the adjustment of

tailgate panel shutlines.

Pivot ball pins for the twin gas struts are screwed into captive nuts in the tailgate inner panel, with the lower

end of each strut anchored to a steel bracket secured to the clamshell aperture. A spring steel clip secures

each strut pivot socket onto its ball pin.

The latch mechanism is secured to the tailgate, and the striker hoop to the clamshell, with a security

system sensing switch incorporated into the latch. The latch release solenoid is mounted to the right of the

striker, and uses a short link to pull a bellcrank lever pivoted on the striker, and interacting with a release lever

on the latch mechanism. The manual release cable activates the same bellcrank lever, and is routed over the

RH wheelarch and through the cabin bulkhead. An adjustable height downstop buffer is provided at each rear

corner of the tailgate for panel height alignment and stability.

The rear aerofoil is secured to the tailgate with 2 x M6 button head screws at each side, and houses the

CHMSL, which comprises 12 red LEDs behind a white diffuser. The CHMSL wiring combined with the latch

sensing switch and HRS wiring, form a tailgate harness which exits the tailgate inner skin near the RH hinge,

to which it is clipped before penetrating the cabin bulkhead.

The heated, toughened glass screen with pre-applied obscuration band, is bonded to the tailgate with an

elastomeric adhesive (see sub-section BV.14).

Tailgate remove/refit

To remove the tailgate:

1. Disconnect the tailgate harness at the RH hinge area.

2. Release the spring clip securing each gas strut to the tailgate and disengage the struts.

To open

HATCH RELEASE LEVER

ohe20

Lotus Service Notes

Section BV

3. Scribe around the hinge blade on the tailgate to aid refit alignment (if applicable) before supporting the

tailgate and removing the hinge blade fixing bolts.

4. Refit in reverse order to removal, adjusting panel shutlines and height as necessary. Check latch engage-

ment and release, and adjust striker position if necessary.

BV.3 - 'A' PANELS

Each 'A' panel constitutes the body surface below the waistline between the front wheelarch and the door

aperture, with each panel screw fixed to the front clamshell and body sill.

'A' panel removal/replacement

1. Slacken or remove the front wheelarch liner and release the two screws securing the 'A' panel to the rear

lower flange of the front clamshell.

2. Slacken or remove the two screws securing the bottom edge of the panel to the body sill and withdraw

the panel.

3. Replace in reverse order to removal.
Front clamshell

Clamshell to wiper bracket

Fixing beneath

nose badge

Clamshell to

mounting

rail

Chassis mounted bracket

Single fixing to clamshell

Clamshell to bumper

Two fixings to clamshell

'A' panel

'A' panel to sill

b358

Lotus Evora. Manual - part 7