Front Clamshell; Front Clamshell Removal/Replacement; Front Bumper - Lotus Evora Service Notes

Lotus Service Notes
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.
Section BV
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