Lotus Eleven/Elise/Exige. Manual - part 20

 

  Index      Lotus     Lotus Eleven/Elise/Exige (engine 1ZZ/2ZZ/1ZR) - service repair manual 2004 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  18  19  20  21   ..

 

 

Lotus Eleven/Elise/Exige. Manual - part 20

 

 

         

        

Lotus Service Notes                                  Section BR

Page 20

BR.12 - ELECTRIC WINDOWS 

(Parts List 11.02)

On cars so equipped, switches for the electric windows are mounted in the front of the door trim panels,

and are operative only with the ignition switched on.  To help locate the switches in the dark, an illuminated dot
is provided in the ‘down’ button which glows amber when the lights are switched on.

To lower a window, switch on the ignition and press the lower, dished end of the switch in the relevent

door.  Release the switch to stop window movement.  To raise a window, press the upper, domed end of the
switch.

The electric operation of the door windows comprises;

-

An electric motor and winder drum assembly mounted on a bracket which is bolted to the door shell.

-

A guide channel for the window lift block, incorporating top and bottom cable pulleys, bolted to the door
shell.

-

A single drive cable running from the window lift block, around a guide channel pulley, through a flexible
conduit, around the motor driven winder drum, through another conduit, around the second guide channel
pulley and back to the window lift block.

-

An adaptor plate bolted to the stud plate on the lower edge of the door glass.

Door Glass Adjustment
-

The door glass guide channels and adjustment procedures are the same as used on manually operated
windows.  Refer to sub-section BR.11.

-

The upstop for the door glass is fitted at the top end of the lift block guide channel in the form of an
adjustable stop screw against which a projection on the window lift bracket abuts.

-

The front/rear height of the top edge of the glass may be adjusted at the slot where the front of the window
lift bracket attaches to the door glass.

Viewed from outboard

Upper guide
pulley

Window upstop

Window lift block

Drive cable

Motor
mounting
plate

Adaptor plate fitted
to glass

Guide channel

Window
winder

Bottom guide pulley

drum

Window lift motor

        b337

         

        

Lotus Service Notes                                  Section BR

Page 21

Replacement of Window Lift Mechanism

The window lift mechanism comprises the motor, drive cable and guide channel assembly as a complete

unit.  To remove the mechanism:
1.

If possible, raise the window fully for optimum access.

2.

Remove the door trim panel and disconnect the window switch.  Peel off the plastic water shielding.

3.

Release the window lift bracket from the door glass and secure the glass in the fully raised position taking
care not to damage the door waist seals in the top of the door shell.

4.

Unplug the motor electrical connector.  Release the three fixings securing the motor mounting bracket,
and the two remaining fixings securing the guide channel to the door shell.

5.

Carefully manoeuvre the lift mechanism from the door.

6.

Refit in reverse order to removal, noting that the motor mounting bracket is fixed directly against the door
shell, but that 4mm plastic spacers are used at each of the three guide rail fixings..

Guide rail

Motor mounting

top fixing

bracket fixings

        b339

Guide rail
bracket fixings

Door shell inner panel

Setscrew and washer

Window lift motor

        4mm
       plastic
       spacer

Threaded
insert

Cable winder

Motor mounting

Guide rail

Guide

drum

bracket

bracket

rail

        b340

         

        

Lotus Service Notes                                  Section BR

Page 22

Note that the door glass is common to manually operated windows, with slider blocks bonded to the front

and rear edges, and a studplate channel bonded to the lower edge.  For electric window operation, an adaptor
studplate is used to provide two studs for the window lift bracket.

BR.13 - DOOR SEALS 

(Parts List 11.01)

Drop Glass 'Waist' Seal

The door drop glass waist seal is a single unit comprising inner and outer seal extrusions joined around

the rear end by a moulded capping piece.  Each length of seal is pressed onto the top edge of the inner or outer
door panel, with a plastic rivet securing the capping piece.  The seal should be removed before withdrawing the
door glass or guide channels from the door.

A 'cheater' seal is bonded to the front and rear faces of the door mirror mounting extension.  To fit a new

seal:
- Clean the bonding surfaces on the door shell edges with Betaclean 3900 (A100B6008V).
- Apply Permabond A905 surface conditioner to the bonding surfaces of door shell and cheater seal.
- Apply Loctite 382 adhesive to the inside of the cheater seal and fit onto the door.

Door Weatherstrip

A hollow section rubber weatherstrip is bonded around the door aperture and roof landings to seal against

the door shell and roof.  Different seal configurations are used for the door and roof areas, with specially
moulded sections to interface with the roof cantrails.  The seal is divided into front and rear sections, with a joint
at the bottom front of each door aperture.

The weatherstrips are manufactured with a self adhesive backing strip.  Before fitting a new seal, the

bonding area on the body must be thoroughly cleaned with Betaclean 3900 (A100B6008V).  In the critical area
of the 'A' post to windscreen header rail corner, an adhesive promoter 3M 4298UV (A116B6000V) should be
applied along the seal path to to ensure optimum seal retention.  Trial  fit the seal before peeling off the
protective backing from the adhesive and applying the seal, ensuring that the moulded sections at the cant rail
interfaces are correctly positioned.

When fitting the rear section of the seal, remove the backing strip from the seal in the section around the

latch plate, and fully insert the weatherstrip nodule into the gap between the 'B' post and rear window shroud.

Weatherstip seal

Seal path

Weatherstrip nodule

Rear window shroud

'B' post

        b335

         

        

Lotus Service Notes                                  Section BR

Page 23

Continue to remove the backing strip and stick the weatherstrip along the seal path down the 'B' post and

along the bottom of the door aperture.  Cut the seal to mate with the end of the front weatherstrip.  Repeat for
the opposite side, and then remove the top section backing strip and secure the seal along the roof shroud
flange.  Use a roller wheel along the whole length of the seal to ensure full adhesion.

A secondary 'J' section seal is applied to the front vertical face of the door shell, linking to the cheater

seal.

BR.14 - DOOR LATCH MECHANISM - Without CDL 

(Parts List 10.17)

Interior release
handle

Exterior release

Relay lever

button

Interior release

assembly

control rod

Exterior
lock
control

Door latch mechanism

rod

Bracket, door beam rear

      b251a

end to door shell

 

 

 

 

 

 

 

Content   ..  18  19  20  21   ..