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Lotus Evora. Manual - part 10

Lotus Service Notes

Section BV

Door glass adjustment

To provide optimum weather sealing, several adjustments are available to position the glass correctly, with

sufficient weatherstrip seal loading.

Glass top edge alignment: When fully raised, the glass top edge needs to be aligned to the roof and cant rail

seal. If adjustment is required, the door trim panel and membrane must first be removed for access (see sub-

section VE.2). The glass is secured to the carriage plate by two rubber lined clamps; release the two clamp

nuts, re-position the glass as necessary and re-tighten.

Glass height adjustment: An adjustable upstop buffer screw is mouted on the carriage plate, which abuts against

a flange at the top of the window lift channel to limit upward travel of the glass. Complete but light contact

between the fully raised glass and cant rail seal is required.

Glass inward tilt: The inward tilt of the glass may be adjusted by screw theaded anchorages for the bottom

ends of the two guide rails. These are accessible with the trim panel fitted. Light contact with the weatherstrip

seals is required.

Door glass removal

1. Remove the door trim panel and membrane (see sub-section VE.2).

2. Remove the door glass waist seal (see sub-section BV.10).

3. Release the two clamps securing the glass to the lift channel, and slide the glass out of the door.

4. New door glasses are supplied with the slider blocks pre-fitted. If a slider block should become detached,

the old adhesive should be cleaned off, the bonding surfaces cleaned with Betaclean 3900 (A100B6008V),

and the following products used to rebond the slider block using the adhesive manufacturer's instruc-

tions:

Permabond Initiator INI 5 A000Z0043F

Permabond Flexon F246 B089B6125V

Guide rail removal

1. Remove the door glass (see above).

2. Release the single screw securing the top of the rail to the bonded bracket or mirror mounting bracket,

noting any shim washers fitted.

3. Release the 2 screws securing the bottom end of the rail to the adjuster screw block, and withdraw the

rail from the door.

Window lift mechanism

The lift mechanism is available only as a complete assembly and is secured to the door shell by three

fixings. The mechanism may be removed whilst leaving the glass and guide channels in place, but access will

be improved if the glass can be fully raised.

1. Release the two clamps securing the glass to the carriage plate.

2. Disconnect the harness from the lift motor and micro switch.

3. Release the three retaining screws and withdraw the lift mechanism from the door.

4. When re-fitting, adjust the glass height and alignment as detailed above.

Lotus Service Notes

Section BV

BV.12 - DOOR LATCH MECHANISM

The door latch mechanism is fitted inside the rear face of the door, which is reinforced by a steel plate

bonded to the composite door shell, and which is also used to secure the rear end of the door beam. The

latch engages with a striker hoop which is secured to a bracket integral with the seat belt mounting frame. The

external key lock (fitted only on the LH door) is connected to the latch mechanism by control rod, as are the

door sill buttons, and exterior release handles. The interior release handle is connected via a control cable.

The latch contains a microswitch to detect when the door is closed, and which is used to operate the courtesy

lamp, alarm system, door glass drop functions, and others. The electrical locking actuator is mounted on a

bracket integral with the latch mechanism with which it interacts via a rotary link.

A plastic security shield is fitted around the latch mechanism to inhibit illicit interference with the locking

system.

Normal operation of the locking functions is performed electronically via the transmitter fob (see Section

MR), but if necessary, the doors can be locked mechanically. The LH door can be locked by using the key in

the exterior lock barrel. Both doors can also be locked individually by lifting the exterior release handle (with

door open), pressing down the door sill button, and keeping the handle lifted, shutting the door. This action will

also disable the interior release handle. Once locked in this way, the RH door can be unlocked only by using

the transmitter fob or by raising the door sill button after opening the LH door via the mechanical key.

WARNING: The window control mechanism includes an automatic window drop and raise logic to aid

door closing and weathersealing. This function may be triggered, with ignition on or off, by door latch-

ing signals. Whenever working on or near the window mechanism, disconnect the window motor to

prevent injury from unintended operation.

Sill button

Security shield

Exterior handle

LH lock barrel Interior release

handle

Latch mechanism

Striker

Interior hoop

release

cable

b362

CDL motor

Tapping plate

Lotus Service Notes

Section BV

Exterior release handle

The exterior release handle is secured to the door shell by two studs. To remove the handle, remove the

door trim panel and membrane (see section VE.2), fully raise the window, and unclip the control rod from the

handle. Release the two retaining nuts, and withdraw the handle.

LH door exterior lock

An exterior key lock is provided only on the LH door. To remove the lock assembly, remove the door

trim panel and membrane (see section VE.2), fully raise the window, and unclip the control rod from the latch

mechanism. Release the three nuts securing the lock mounting plate to the door, and withdraw the plate and

lock assembly. A spring clip secures the lock to the mounting plate.

Latch mechanism

To remove the latch mechanism:

1. Remove the door trim panel and membrane (see section VE.2).

2. Fully raise the window and unclip the exterior lock rod from the latch (LH door only).

3. unlip the control rod from the exterior release handle.

4. unclip the interior handle release cable from the latch.

5. unplug the door harness from the latch actuator, and the microswitch.

6. Release the three screws from the door shut face securing the latch mechanism, and withdraw the unit

together with the sill button control rod from the door.

7. On re-assembly, remember to fit the sill button control rod to the latch mechanism before installing the

mechanism into the door.

BV.13 - WINDSCREEN REMOVAL/REPLACEMENT

The Evora windscreen is constructed from two layers of glass, the inside component of which is green

tinted, sandwiching a synthetic solar reflecting interlay, to form a 5mm thick laminate. A black ceramic obscura-

tion band with graduated fade out, is applied to the inner surface periphery. The windscreen is bonded to the

composite body frame using an elastomeric polyurethane adhesive, and contributes to the structural integrity

of the body assembly. The screen uses rubber extrusions along the top and bottom edges for visual enhance-

ment, and black finished alloy finishers over each 'A' pillar. Screen replacement will require new top and bottom

filler strips, but the side finishers may be salvaged if carefully removed.

Parts required:

Windscreen.

Betaseal Kit A075B6158F.

Plinth, interior mirror mounting (supplied with new windscreen).

Plinth Adhesive Kit A116u0194F.

Top and bottom filler strips.

1. Pull the door weatherstrip off the windscreen frame flange along both 'A' pillars. Remove the 'A' pillar

finisher fixing nuts; one at the lower end beneath the corner of the clamshell; three along the 'A' pillar shut

face. use a knife blade or similar between the glass and the finisher to gently ease the finisher away from

the double sided tape fixing. Withdraw the finisher with the secondary door seal still attached and secure

aside with tape.

2. If a cutting wire is to be used to release the windscreen bonding, it may not be necessary to disturb the

front clamshell. If a vibrating knife is to be used, it is likely that the rearmost fixings for the clamshell will

need to be removed to allow tool access to the bottom corners of the screen.

Lotus Service Notes

Section BV

3. Slide the interior mirror stem from the windscreen plinth. Remove the sun visor retaining screws to allow

the front of the head lining to drop. Pull each 'A' pillar trim panel out from its three captive 'fir tree' fasteners

(a fourth fir tree button at its lower end is inaccessible), to protect from adhesive cutting tool damage.

4. Remove the windscreen wiper arm and attach suction handles to the glass. using a cutting wire or dedi-

cated vibrating knife of suitable form, cut the adhesive bead around the entire periphery of the screen,

taking precautions as necessary to prevent paint or body damage. Note that the top and bottom rubber

finisher strips are likely to be cut through during this operation and will require replacement. With assist-

ance, lift the glass from the car.

5. Remove old adhesive from the windscreen frame sufficiently to leave a consistent and flat surface for the

new bonding medium.

6. Clean the whole of the windscreen periphery bonding surface, including the mirror plinth area with the

wipe cleaner supplied in the Betaseal Kit, or with Betaclean 3900 (A100B6008V). Allow to dry.

7. Prime the bonding surface of the new mirror plinth and the corresponding glass area with Dymax 500E

activator A111B6187. use Dymax 840 adhesive to bond the plinth to the glass following the supplier's

directions. Position the plinth centrally and with the bottom, closed end, 7mm from the bottom edge of

the obscuration patch.

8. Prime the bonding area on the glass to a width of 25mm with Betaprime 5500 (green cap) A120B6041V,

avoiding the VIN window. Allow the primer fully to dry.

9. Fit the new self adhesive filler strip A132u0266F to the inside top edge of the glass, and the longer strip

A132u0402F to the bottom edge.

10. Prime and re-activate the prepared surface of the old adhesive on the windscreen frame with Betawipe

4000 (A082B6355V). If the windscreen frame surface is new or without adhesive, prime the frame with

Betaprime 5404 (red cap) A082B6337V. Allow a minimum of 5 minutes for the primer to dry. If the screen

is not fitted within 48 hours, the primer should be re-applied.

11. Around the windscreen landing path, check the joints between windscreen frame and screen lower land-

ing, and between the roof and body side 'A' pillars, for correct sealing and joint path integrity. If necessary,

prepare these gullies for bonding as described above, and fill with adhesive sealant prior to windscreen

fitment.

12. Cut the nozzle of the adhesive cartridge to

the dimensions shown to produce a triangular

section bead. Holding the cartridge perpen-

dicular to the glass, extrude a bead of Beta-

seal 1701 adhesive (A082B6281F) around

the screen using the inner edge of the top and

bottom filler strips as a guide, and following

the centre of the primer band along each side.

8 mm

12 mm

60 mm

b264

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