Lotus 2004 Eleven Service Notes page 69

Lotus Service Notes
6. Release the six (USA market) or eight (other cars) screws securing the fuel filler neck to the clamshell.
Withdraw the filler neck from the clamshell aperture, noting the earth braid secured to the roof hoop
backstay. Keep the filler cap fitted to minimise vapour hazard.
7. Remove the air filter box intake scroll, and from inside each rear wheelarch, release the air intake grille
fixings, and the two screws securing the clamshell to the waistline joint of the sill panel. Withdraw each
grille from its retaining clip.
8. Remove the battery and feed the battery cables through the clamshell grommet. Disconnect the rear
harness and rear lid switch harness from the area behind the battery, and feed through the clamshell
grommet.
9. Remove the rear diffuser panel.
10. From inside the luggage area, release the two screws each side securing the boot floor to the subframe.
11. Unhook the washer bottle.
12. Withdraw the clamshell from the car, noting any spacer pads fitted on the subframe.
13. Refit in reverse order to disassembly with the following notes:
Shimming of clamshell floor mounting points:
It is most important to maintain a gap of at least 7mm between the phenolic resin heatshield rivetted to
the underside of the clamshell boot floor, and the exhaust muffler corrugated heat shield bolted to the sub-
frame. The corrugated shield must touch neither the muffler, nor the clamshell mounted shield, or heat dam-
age may be caused to the clamshell.
On factory build, the subframe is marked adjacent to each of the four clamshell mounting points with the
shim thickness required. Shim plates are available in 1mm and 2mm thicknesses. If a new subframe is being
fitted, or the markings are not visible;
- Use a straight edge across the clamshell rear mounting points on the subframe, and measure down to the
muffler heatshield. Sufficient shims need to be used to bring this dimension to a minimum of 7mm.
- With these shimplates fitted, trial fit the clamshell and if necessary add further shims to optimise the fit of
the clamshell with respect to sill and door shutlines.
- Measure the shim gap at the boot floor front fixing point.
- Remove the clamshell, fit the required shim plates onto the subframe and refit the clamshell.
BR.8 - DOOR MIRRORS
The manually adjustable, plastic housed
door mirrrors, are mounted via an injection
moulded plinth to the door shell. A spring
loaded ball and socket arrangement provides
a means of mirror adjustment, and a sprung
attachment of the mirror housing to the pivot
socket allows for the mirror to move forwards
or backwards on accidental contact, in order
to reduce the potential for personal injury or
vehicle damage.
Page 12
Mirror housing
Mirror glass & surround
Section BR
b240