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A little insight into the Headlight condensation issue
(Sorry it is long but hopefully helpful)
(Sorry it is long but hopefully helpful)
I was really getting tired of my 2007 headlights getting condensation in them. The 2007 model year and onwards are “sealed beams” meaning that the clear lens does not separate from the bulb housing as it does in 2005 – 2006. Even when under warranty, I asked the dealer and they said that this is normal. I also checked with Lotus USA and basically received the same answer, telling me that some have it while other don’t and that it is one of those things with these cars. (not acceptable but what can you do).
The entire headlight assembly is held with three (3) - 17mm nuts and one (1) - 8mm nut. Also a point to be noted is that Lotus put moisture absorbent package (quite a large one) inside each of the assembly. There is small hole/slit towards the bottom front of the headlight assembly if you look closely. This is where the condensation usually starts (see picture).
After reading many of the post on how to prevent condensation, I used liquid (windshield) silicone to go around the lens housing to make sure that there were no leaks from where the lens is glued to the bottom assembly. I also removed the bulb covers/dust covers (low and high beams from the back) cleaned and reinstalled them to make sure that there were no leaks. Also checked all the other rubber grommets. But despite all this, I was still getting condensation.
Reading on other posts regarding condensation in sealed beam headlights, I came to find out that that even sealed beams do have a vent hole. While some are clearly seen as there is usually a small pipe attached to one corner, other at times are hidden and difficult to see as they might be some sort of a flap. Basically it is there because the air inside the lens /headlight housing needs to expand when heated and also to allow the venting of moisture rich air inside. I looked on a few headlamps on other cars and found the vent pipes on them. But looking at the Headlamp on the Elise, I did not see any. So after pulling the assembly out once again to try to figure out a solution I saw that at the back of the assembly there are these three grey caps (see picture) covering something. One towards the bottom, one around the center and one towards the top. At first I thought that they must be some sort of adjustment holes but they are not. After I removed the one closer to the front-bottom, I put a little wire inside to see where it goes. It went inside the assembly closer to the hole/slit that is towards the front -bottom of the headlight. As soon as I removed it the condensation started to disappear rapidly!! So I decided to see what this “Cap” was all about. As you can see in the other pictures that there is a black rubber piece inserted within the grey cap. I took it out and on the other side of it is a paper/fabric type of material that seems to be “breathable” meaning that it would let the air pass through without dust getting in. This goes to tell me that for some reason the moisture rich air inside the headlamp assembly is not able to escape and thus condenses on the lens.
So I am going to try two options, one just install the black rubber part without the grey cap and see what happens or remove it all and attach some type of pipe for the air to escape out of the housing (possible a bent pipe as I have seen on other cars.
(UPDATE: Well I installed a “L” shaped pipe but condensation is still there)
Let me know what you all think (or someone that has figured out a good solution). Hopefully this sheds some light on this issue. It is really bad to see that such a great car has condensation issues.
