Lotus Eleven/Elise/Exige. Manual - part 19

         

        

Lotus Service Notes                                  Section BR

Page 16

When refitting the door, take care not to scratch the glass if this is contained in the door.  Insert the two

rear bolts securing the beam to the latch bracket, but do not tighten until the three fixings securing the front of
the shell to the beam flange have been fitted and tightened.

BR.11 - DOOR GLASS, GUIDE RAILS & WINDER MECHANISM - Manual Windows

A manually operated door window scissor type lift mechanism is used in conjunction with two steel guide

rails and a ’frameless’ door design.

The operating principle of the window lift mechanism is that of a scissor linkage, with the front lower end

of the primary leg anchored to the door shell, the lower end of the secondary leg sliding in a horizontal channel
on the door shell, and the upper ends of both legs sliding in a channel fixed to the bottom edge of the window.
The geometry of the system provides for a parallel lift of the glass, where the angle of the bottom edge does not
change throughout the range of travel.  An extension to the primary scissor leg carries a toothed sector which
is engaged by a pinion on the window winder.  The front and rear edges of the glass are guided by steel rails
which engage with point contact Nylon guide blocks bonded to the glass.  The bottom ends of the rails are
adjustable in/out to set the inward tilt of the glass, with the 'up' glass position controlled by an eccentric stop on
the winder mechanism.

Door glass adjustment

To adjust the door glass for optimum weather sealing and ease of operation:

1.

Fit the soft top roof and fully raise the window.  Check the alignment of the top edge of the glass against
the seal, and the seal compression along the cant rail and up the 'A' and 'B' posts.  A light compression is
required; just sufficient to ensure sealing, without imposing loads on the winder mechanism.

2.

To adjust the inward tilt of the glass, screw the adjusters at the bottom of each guide rail in or out as
necessary.  Access is available without removing the door trim panel.  Check that the window glass
moves freely throughout the range of travel.

Beam to extension

Door beam

Captive

Door beam

bracket fixing

extension

fixing

flange

bracket

Door
beam

Door shell to
extension
bracket fixing

Door shell to
beam fixing

      b245a

         

        

Lotus Service Notes                                  Section BR

Page 17

Door glass
lift channel

Nylon guide
block

Door glass

Guide rail

Scissor

Door

Steel guide

tilt

top fixing

linkage

glass

rail

Adjuster

Handle pinion

screw

Reaction

Toothed sector

channel

Threaded
block fixed

Door

to rail

anchorage
point

      b285a

Threaded block
fixed to door shell

         

        

Lotus Service Notes                                  Section BR

Page 18

3.

To adjust the alignment of the top edge of the glass, it is necessary to adjust the height of the reaction
channel.  Remove the window winder handle and door trim panel, slacken the reaction channel fixings,
and move the channel up or down as required.  Raising the channel will raise the rear edge of the glass.

4.

To adjust the fully up position of the glass, the eccentric stop on the toothed sector of the winder mecha-
nism must be rotated as necessary.  A mesh friction washer is fitted between the eccentric and the sector
to help retain adjustment.

To replace the door window glass
1.

Remove the window winder handle, and the door trim panel.

2.

Release the three fixings securing the slider channel to the bottom of the glass.

3.

Do not attempt to withdraw the glass from the door without first removing the door waist seal.  Carefully
prise the one-piece seal off the door shell inner and outer flanges, and release the push fixing from the
seal moulding at the rear end of the door.  Withdraw the glass from the door shell.

4.

Note that new door glasses are supplied complete with jig bonded Nylon sliders and stud plate.

5.

Fit the new glass into the door and re-assemble in reverse order to the above.

6.

Adjust the glass position as detailed above.

To replace door winder mechanism
1.

Remove the window winder handle, and the door trim panel.

2.

Release the interior release control rod from the door handle and unclip from the latch mechanism.

3.

 Secure the door glass in the fully raised position, and release the three fixings securing the winder
mechanism to the door;
-

two fixings adjacent to the winder spindle;

-

on fixing through the static pivot of the primary scissor arm

4.

Manoeuvre the mechanism to free the winder spindle from the door, and to disengage the two upper
sliding bosses of the scissor arms from the window channel, and the lower sliding boss from the static
reaction channel.  Withdraw the mechanism from the door.

5.

Before fitting a lift mechanism, lubricate the three slider bosses and the sector teeth with Century Luplex
M2 grease (or similar).  Fit the mechasnism into the door and engage the three slider bosses in their lift
and reaction channels before securing with the three fixing screws.  Note that a single M6 spacer washer
is used between the pivot of the primary scissor arm and the door shell.

Mesh friction washer

Winder spindle

Eccentric stop

Toothed sector

        b274

         

        

Lotus Service Notes                                  Section BR

Page 19

Door glass
slider block

Winder mechanism

Lift channel

Door glass
stud plate

        b321

Reaction

Scissor arm

Winder

channel

pivot fixing

mechanism
fixing

6.

Adjust the glass upstop postion, top edge alignment and inward tilt as detailed above.

Door glass guide rails

Two guide rails are used for door glass; one for the front and one for the rear edge.  Each of the steel,

black zinc plated, guide rails, is secured by a single screw at the top end to a jig bonded bracket in the door
shell, and by a threaded adjuster at the lower end, engaging in a threaded block fixed to the door shell.
Screwing the adjusters in or out will set the inward tilt of the glass and the contact between glass and door
weatherseal.

To remove a guide rail, first remove the door glass (see above), before releasing the single screw at the

top, and releasing the threaded block from the door shell.