Lotus Elise S1 Service Notes page 38

Lotus Service Notes Section BM
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 requires cutting with reciprocating knife, and access to the joints is sometimes ob-
scured. 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 BN.4), and for improved access,
the two doors.
2. Unbolt the topshell mounting bracket at each bottom corner of the windscreen (bracket is bolted through
the 'A' post panel to a tapping plate bonded to the windscreen frame).
3. Remove the windscreen (see sub-section BN.13).
4. Remove the instrument binnacle and dash panel (see sub-section BN.12).
5. Release the brake hose/pipe connector at the front end of each buttress on the windscreen frame.
6. Disconnect the wiper motor harness and windscreen washer tubing. Release all relays, fuses and har-
nesses from the buttresses as necessary.
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7. Use a sealant cutting tool to cut the bond between the buttresses and chassis, buttresses and sill panels
and between the demist duct and dash baffle.
Note:
The joint between the frame and the dash baffle panel is joggled, and in order to avoid damage to
the baffle, the windscreen frame may require cutting to allow sufficient access.
Demist duct
Bonded joints
Fascia top
Dash baffle
Chassis scuttle
There is a short length of vertical joint where the buttress overlaps the sill flange where the sill
flange is bonded to the chassis. It may be necessary to cut the buttress around this part of the flange in
order to remove the frame, and then to remove the remaining buttress flange from the sill.
After releasing the entire bonded joint, some manoeuvring of the frame will be needed to withdraw
the frame from the baffle panel.
8. Release the wiper motor mechanism, windscreen washer jets, gutter and demist vents for transfer to the
new frame.
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