Lotus 2004 Eleven Service Notes page 56

Lotus Service Notes
To replace the rear bulkhead:
1. Remove the rear clamshell (see sub-section BR.6).
2. Remove both seats, and the bulkhead interior trim panel.
3. Remove from the inside of the bulkhead the microwave sensor and immobiliser module. Release all wiring
harnesses from the bulkhead clips.
4. Release all fittings from the roll-over bar backstays (air cleaner, roll over valve) and remove both back-
stays.
5. Taking suitable precautions, remove the fuel filler hose and filler breather hose, and cap the tank apertures
to prevent dirt ingress and reduce fire risk.
6. Release the evaporative emissions charcoal canister and fuel filter from their bulkhead mounting brack-
ets.
7. Release the aerial lead from the bulkhead.
8. Using a long knife, cut the adhesive securing the insulator panel to the bulkhead, and remove the panel
to improve access to the bulkhead bonded joint.
9. Using a sealant cutting knife, cut the adhesive bead between the top section of the bulkhead and the roll
over bar, and between the bottom of the bulkhead and the chassis. If the sill panels are fitted, cut the
bond between sill panel 'B' posts and the bulkhead panel.
10. Manoeuvre the bulkhead from the car.
To Fit Bulkhead Panel
Before fitting a bulkhead panel, ensure that the following parts are bonded to the panel:
- Header tank mounting bracket;
- Charcoal canister mounting bracket;
- Immobiliser module stud plate;
- Fuel filter mounting bracket;
- Rear window glass;
All the above components are bonded using elastomeric adhesive applied as follows. Refer also to sub-
section BQ.5:
Brackets & Studplates: Clean the bonding surfaces on the bracket and bulkhead with Betaclean 3900 (black
cap) and prime both surfaces with Betaprime 5404 (red cap). Apply Betaseal 1701 adhesive to the bracket,
and clamp in position until the adhesive has cured.
Rear Window: Clean the whole of the bonding surface on the glass with Betawipe VP 04604 (yellow cap), and
prime with Betaprime 5001 (green cap). Clean the corresponding surface on the bulkhead with Betaclean 3900
(black cap) and prime with Betaprime 5404 (red cap). Apply a bead of Betaseal 1701 to the periphery of the
glass, and press into position on the bulkhead to ensure sufficient compression of the adhesive. Use a spatula
to remove excess extruded adhesive and smooth any visual areas. Tape the glass into place if necessary to
retain position until the adhesive cures.
Bonding of Bulkhead Panel: Clean the mating surfaces of bulkhead, roll over bar and (if fitted) sill 'B' posts,
with Betaclean 3900 (black cap) and prime with Betaprime 5404 (red cap). Or, where applicable, use Betawipe
4000 to re-activate old adhesive (refer to sub-section BO.5). Clean the mating surface on the chassis with
Betawipe VP 04604 (yellow cap), and prime with Betaprime 5404 (red cap). Apply a bead of Betaseal 1701
to the bonding path on the bulkhead, and manoeuvre into postion, pressing all round the joint path to ensure
sufficient compression of the adhesive. Use a spatula to remove excess extruded adhesive and smooth any
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Section BQ