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Posting this in the how-to section now:

I finished my guide on how to change the AC condenser on an Evora (and Evora 400). I put the digital version up for free here: Lotus Evora

From the beginning I wanted this to be a nicely printed hard copy guide too; I simply prefer using them while working on a car and I like how they look on my shelf. I'm only selling these hard copies on eBay, though, as I've been told that the forum's existing policies prevent that kind of solicitation from non-vendors. As I only have a few of these to sell, I wouldn't be able to justify becoming a full blown vendor. Thus I won't link to it here.

Anyway, I hope this helps some people have an easier time with this somewhat common problem. As always, let me know on the forums or over e-mail if you have any comments, questions, criticism, etc.

agentdr8 has already pointed out one very good addition:

EDIT: Looking over your guide, and it's very well laid out. I would add another step or add some wording to section 4.4, between steps 4 and 5. After starting the car, before disconnecting the battery, you should wait at least 30 mins for all systems to properly shut down.
which I'll certainly add to Revision B

Enjoy!
 

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Followed this guide to replace my condenser a few weeks ago, very detailed and helpful as there are a number of parts and designs that only a small volume company like Lotus would still use. Thanks to MGB for putting it together, below are some thoughts.


Pulling the headlight washer hoses is indeed a pain, I wasn't comfortable pulling the washer units off the headlights so I used a heat gun to warm up the hoses and they came off without much trouble. You'll need to plug up the hoses or be prepared to drain the entire reservoir, up to a gallon. I don't know how MGB got the lights out without removing the rear brackets, I didn't want to mar any surfaces so I marked them then removed.

I found removing the badge to be tricky, I kept breaking dental floss and moved on to low test fishing line, before realizing there are two studs on the back of the badge that align it to the body. Once you've cut the adhesive with floss from above and below, take a plastic pry tool and it will pop out easily.

The bracket holding the two refrigerant lines into the condenser is not visible, it's a bit tricky to put back together. The lines and condenser openings are all aluminum and flexible, a bit of massaging may be required.

Four new seals from Lotus (A082P607F and A120P6002H) are cheap (~$7), I didn't want to play around with generic sizes. The dryer (A132P6011F) is around $90, sounds like there may be aftermarket options now.

Fitting the bumper cover can be done alone but a second set of hands is valuable here as it's big and flexy.

Aligning the headlights is fiddly but there's plenty of adjustability.

Spray adhesive does a good job or reapplying the foam pieces on the sides of the plastic air intake.

Mesh: definitely do something here or you'll be facing the job again in the future. I went with CCG 12'x48' small diamond grill from Amazon, about $60. It's plastic coated aluminum, very easy to cut and shape and looks good. I left the stock piece on and applied this behind, doesn't look out of place and is secured with the factory nuts.


All in all not a bad job, some strange design decisions from Lotus (why so many different and loose spacers for the undertray?), this should be sorted for a long time now.
 

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To get the headlight washer hose off I just pulled off the clip that was holding the hose end to the headlights and it just came off easily when I was clam off to replace hood vent louvers. The PDM is linked in the first post, end of second sentence.
 
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