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Lotus Elise / Lotus Exige. Manual - part 19

Lotus Service Notes Section BR

Page 30

Airbag Type

Instrument pack
mounting bracket

Column shroud
support leg

Fascia top panel

Column
shroud

Dash fixings
to screen
frame

FLV/audio
housing

Climate
control

Airbag

housing

door

Airbag shute

Dash upper
extrusion

Dash lower
extrusion

Audio set
support

Rivet to scuttle beam

pl1405mtb

Lotus Service Notes Section BR

Page 31

To Remove Fascia Top Panel - airbag cars

WARNING: The airbag Sensor & Diagnositic Module can maintain sufficient voltage to cause an airbag
deployment for up to 20 seconds after the battery has been disconnected. Before working on the
airbag system, or in close proximity to an airbag, first take the following precautions to disable tempo-
rarily the airbag system:

Turn off the ignition.

Before disconnecting the battery, use the Lotus Scan tool to read any stored trouble codes.

Disconnect the negative (earth) lead from the battery and tape back to ensure that no contact with the
battery negative terminal can be made.

Wait for 30 seconds.

If working on or near the steering wheel, locate the yellow harness connector alongside the steering
column near the column upper fixing. Unplug this connector. Note that the connector is fitted with
'shorting bars' which automatically interconnect the high and low terminals of the airbag to prevent acci-
dental deployment caused by a voltage differential.

When service work has been completed, reconnect the harness plug and secure with its locking feature,

and reconnect the battery. Ensure the airbag tell tale lights for a few seconds with ignition and then goes out.

Column shrouds: Remove the two screws retaining the top part of the shroud, and the four screws
retaining the lower part, and withdraw both parts from the column.

Instrument shroud: Pull the instrument shroud backwards to release the four spring clips from their
apertures in the dash panel.

Sill top trims: Release the two screws at the bottom of the coin pockets at the front of each sill, and pull
the sill top trim panels from the chassis.

Dash end panels: Release the two screws within the top of each coin pocket, and withdraw the switch
panel (driver's side) and blanking panel (passenger side) from the dash end panel. Unplug the wiring
harness from the switch panel.
From within the aperture, release the two screws retaining each end panel to the dash, and pull the panel
rearwards to withdraw the spring clips in the top of the panel from the dash.

Airbag door: Pull the airbag door away from the dash, which action will probably require the four retaining
clips to be renewed. Note that the door is constrained by two tether straps.

Centre vent panel and radio surround: Release the two screws at each side of the panel and withdraw the
panel from its two spring clips.

Fascia top panel: Remove the 5 screws securing the rear edge of the panel to the dash rail, and withdraw
the panel rearwards to disengage the two spigots from the base of the windscreen surround. Disconnect
the speaker cables.

Refit in reverse order to removal.

Lotus Service Notes Section BR

Page 32

BR.17 - WINDSCREEN

(Parts List 11.01)

The laminated windscreen, together with self coloured synthetic finisher moulded around the top and side

edges, is bonded to the composite windscreen mounting frame using Betaseal flexible polyurethane adhesive.
It is not practicable to remove a windscreen from a car and then refit the same glass, as removal of the screen
will require cutting the surround finisher which is available only as part of a new windscreen assembly.

To Replace Windscreen
Parts required:

Windscreen
Betaseal Kit A075B6158F
Plinth, interior mirror mounting
Plinth Adhesive Kit A116U0194S

On non-airbag cars, to minimise the possibility of trim damage, remove the fascia end (speaker) panels,
and the fascia top capping panel (around inside base of windscreen).

Remove the front clamshell (see sub-section BR.6).

Remove the wiper arm from its spindle, and the interior mirror from its plinth.

Cut around the whole length of the windscreen surround finisher to allow access to the 'screen adhesive
joint. Apply suction handles to the outside surface of the screen.

In order to incur the minimum risk of damage to the windscreen composite mounting frame, the preferred
method of cutting the windscreen adhesive is by the use of a 'cheese' wire. Protect the visual surface of
the windscreen frame with tape before commencing the cutting operation.

Screen removal tool

Cutting wire

b322

Lotus Service Notes Section BR

Page 33

After cutting out the screen, remove old adhesive from the windscreen frame sufficiently to leave a
consistent and flat surface for the new bond.

Clean the whole of the inside surface of the windscreen with a 50% solution of water and isopropanol.
Allow to dry.

Fit the interior mirror plinth to the inside of the windscreen using the adhesive kit and instructions sup-
plied.

Clean the whole of the inside surface of the obscuration band, and the bonding surface on the windscreen
frame with the wipe cleaner.

10.

Apply a 25 mm wide band of Betaprime around the inside periphery of the glass. Similarly apply to the
whole of the bonding surface on the windscreen frame, and to the windscreen bottom laminated edge.
Allow to dry for a minimum of 5 minutes. If the screen is not fitted within 48 hours, the primer should be
re-applied.

11.

Cut the nozzle of the Betaseal cartridge
to the dimensions shown to produce a
triangular section bead. Holding the car-
tridge vertically, extrude a bead of ad-
hesive around the screen, using the edge
of the finisher as a guide along the top
and sides, and following the centreline
of the primer band along the lower sec-
tion.

Windscreen top edge

Screen centreline

Obscuration

79mm

band

Mirror position on

63mm

Mirror position on

RHD offset to left

LHD offset to right

b263

8 mm

10 mm

60 mm

b264

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