Lotus 2004 ELISE Service Notes page 36

Lotus Service Notes
The shape of the frame is critical to the windscreen fit, and structural repairs to the frame itself are not
recommended. It is not generally economic to attempt to remove the windscreen frame intact for refitment,
as the elastomeric adhesive bonding the frame to the chassis requires cutting with a reciprocating knife, and
access to the joints is sometimes obscured. The recommended procedure is to cut the frame as necessary to
allow its removal without damage to the dash baffle panel. If the sills are to remain fitted, it will be necessary
to carry out some minor work on the screen buttress to sill panel joint, where a panel overlap occurs.
To Replace Windscreen Frame
1. Remove the front wheelarch liners and front clamshell (see sub-section BR.5), and for improved access,
the two doors.
2. Remove the windscreen (see sub-section BR.14).
3. Remove the instrument binnacle and fascia top panel (see sub-section BR.13), and release the fixings
between dash upper extrusion and screen frame.
4. Release the brake hose/pipe connector at the front end of each buttress on the windscreen frame. Release
all harnesses and other components from the windscreen frame buttresses as necessary.
5. Remove the wiper motor mechanism from the windscreen frame.
6. Use a sealant cutting tool to cut the bond between the windscreen frame buttresses and chassis, and
between the frame and 'B' posts, and between the frame underside and dash baffle panel. Remove the
windscreen frame.
7. Cut the adhesive securing the drainage gutter around the front of the frame, to allow transfer to the new
frame.
8. If the dash baffle panel is to be replaced, the clutch pipe and climate control cables must be released and
threaded through the panel before cutting the adhesive.
Dash baffle panel
Foam strip
sn_bq_cyclone.indd 13
Primer band on chassis
Primer band on baffle
Section BQ
Heater pipe grommet
b283b
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