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Lotus Evora. Manual - part 9

Lotus Service Notes

Section BV

To remove/refit rear bumper

1. From inside the boot, remove the trim panel from around the latch mechanism, and disconnect the har-

nesses to the rear fog and reverse lamps, parking sensors and reverse camera.

2. From within each rear wheelarch, release the single fixing securing the lower edge of the bumper to the

subframe bracket, and the two fixings at each side securing the diffuser finisher to the diffuser. Also release

the single fixing securing the top edge of the bumper to the clamshell flange.

3. From within each side of the boot, remove the two grommets, and release the two fixings securing the

bumper top edge to the clamshell. Also remove the single screw just outboard of the tail lamp.

4. Remove the 5 fixings along the rear edge of the boot aperture, clamping the bumper to the clamshell.

5. Carefully withdraw the bumper from the clamshell.

6. Refit the bumper in reverse order to removal, adjusting the panel heights and gaps as necessary.

BV.8 - DOOR MIRRORS

The two door mirrors are electrically adjustable, and, only when the engine is running, are heated on de-

mand in conjunction with the HRS for a maximum period of 10 minutes. An optional specification includes an

electric fold facility for use when parking or negotiating narrow gaps.

Each mirror comprises a cast alloy bracket carrying a black textured plastic housing, and a gimbal mounted

glass carrier driven by a pair of electric motors, and to which is attached the mirror glass. A third motor provides

the fold function. A sprung attachment of the mirror housing to the plinth allows the mirror to move forwards

or backwards on accidental contact, in order to reduce the potential for personal injury or vehicle damage. A

body colour painted moulding is clipped to the front of the mirror housing.

This mirror assembly is mounted via a cast alloy plinth to the door cheater panel, with upper and lower

black plastic mouldings used for cosmetic enhancement.

Replacement of mirror glass and cover

The mirror glass is contained in a plastic carrier which includes the heating element and terminals. To

remove the glass, press the glass so as to expose the outer edge, and carefully ease the outboard end from

its carrier clip. Then unhook the inboard end, unplug the two heater cables, and remove the glass. Check that

the adjustment racks have not become detached from the gimble during disassembly.

Mirror cover Mirror body Plinth upper

moulding

Cast alloy

plinth

Plinth lower

Harness connector moulding

b360

Lotus Service Notes

Section BV

To refit, connect the cables (either way round), hook on the inboard end of the glass carrier, and press the

outboard end until the clip is engaged.

Note that convex glass is normally fitted to both sides in order to provide the widest field of vision, but

certain markets use flat glass on one or both sides. Be aware that objects viewed in convex mirrors appear

more distant than when viewed with flat glass.

The painted cover is secured to the mirror body by integrally moulded clips. To remove a cover, first remove

the glass to allow the lower clips to be eased, whilst the lower edge of the cover is carefully prised away.

Replacement of mirror assembly

To remove the complete mirror, the assembly of mirror, plinth and covers must be released from the

door:

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

2. unplug the mirror harness connector, remove the split grommet and back feed the harness into the door

shell. use the harness hole to access and remove the mirror plinth lower fixing screw.

3. Remove the Rokut plastic rivets securing the plinth upper finisher and cheater panel seal to the door. Pull

back the cheater seal to access and remove the plinth upper fixing screw.

4. Withdraw the mirror assembly whilst feeding the harness through the door shell.

5. Remove the plinth lower cover by releasing the two retaining screws.

6. To allow the mirror to be removed from the plinth, the connector block must first be removed. Record the

cable colour against connector cavity before using a suitable terminal extractor tool to depress the retain-

ing barb, and withdraw each terminal from the connector. Remove the three screws around the pivot

mechanism and withdraw the mirror from the plinth.

Note that the plinth upper finisher is heat bonded to the plinth. If necessary, new parts can be mated using

a soldering iron or similar to secure.

7. New mirror assemblies may be supplied with an unsuitable connector block. use an appropriate terminal

extractor tool to withdraw each cable from the connector, which may then be discarded. Feed the harness

through the mirror plinth before inserting the terminals into the replacement or original connector block in

the following manner.

Connector cavity Cable colour Function

1 Not used Not used

2 Brown up/down

3 Orange Mirror common

4 Pink Left/right

5 Red Fold in

6 Blue Fold out

7 Black Mirror heater

8 Black Mirror heater ground

8. Continue re-assembly in reverse order to removal.

BV.9 - DOOR SHELL, BEAM & HINGES

The door comprises an inner and outer composite moulding, bonded together around the periphery, and

enclosing a hollow section, extruded alloy, door beam with internal siffening webs, to provide side intrusion pro-

tection. A fabricated steel hinge post is bonded to the inside of the door shell front face, and provides a 2-bolt

mounting for the front end of the door beam. Similarly, another fabricated steel bracket is bonded to the inside

of the door shell rear face, and provides a 2-bolt mounting for the rear end of the door beam. The components

so far described, are available only as a jig-built, door shell assembly.

Each door uses two identical hinges, each comprising two steel forgings, one with a single eye for bolting

Lotus Service Notes

Section BV

to the door shell, and one with a double eye for bolting to the chassis hinge post, the oversize holes providing

sufficient positional tolerance for door shutline adjustments to be made. Synthetic bushes and a steel tube

provide the maintenance free pivot mechanism, with the two hinge halves being mated by a pivot bolt to allow

door removal without losing the alignment settings. The hinges also feature open limiting stops, although this

function is subsumed to the check strap.

A check strap is fitted to limit door opening and also to provide a mid-point detent position for convenience

in restricted space. The check strap unit is secured to the inside front face of the door shell with two screws, and

uses spring loaded Nylon jaws to embrace a profiled steel link fixed by a single bolt to the chassis 'A' post.

To remove/refit door assembly

The complete door assembly may be removed from the car by the following procedure:

1. Remove the door hinge post trim panel and unplug the door harness connector. Feed the connector

through the hinge post aperture.

2. Release the check strap from the 'A' post.

3. To preserve the shutline settings, support the door, remove the pivot bolt from each of the two hinges, and

lift the door off the hinge pivot tubes.

4. Refit in reverse order to removal. If shutline adjustment is required, slacken the bolts securing the hinges

to the door and 'A' post, move the door as required, and re-tighten.

Check strap

The check strap is secured from inside the door shell by two M6 screws. To remove the strap, remove the

door trim panel and membrane, fully raise the window, and release the two screws securing the check strap

assembly. Remove the single fixing securing the strap to the 'A' post, and withdraw the strap.

BV.10 - DOOR WEATHERSTRIP SEALS

Drop glass waist seal

The door drop glass uses flocked EPDM wipe seals on the inner and outer top edges of the door shell to

minimise water ingress into the door. Each main length of seal is bonded to an aluminium 'u' section barbed

carrier, which is pressed on to the appropriate door top flange. These two seals are linked around the back

of the door shell glass slot, by an integrated moulded capping section secured to the door by two push button

fixings. The seal should be removed from the door before attempting to remove the door glass or guide rails.

To remove the seal, lower the door glass fully. Press in the centre pin of the two button fixings to allow

them to be withdrawn, and carefully pull the two seals from the door shell flanges.

Door cheater seal

The extension to the top front of the door moulding, designed to provide increased support to the door

glass, and also to mount the door mirror, is referred to as the door 'cheater' panel. A moulded rubber seal is

fitted around the cheater and secured by Rokut rivets and adhesive strips.

Door weatherstrip

Each door weatherstrip seal comprises several extruded rubber sections and a right angle corner mould-

ing, all bonded together to form a single service unit. The top, front and rear sections of the seal incorporate

a gripper channel which is pressed onto the body flange. The bottom section is bonded to the sill via a self

adhesive strip pre-applied to the seal. Before fitting the seal, thoroughly clean the bonding area on the sill us-

ing Betaclean 3900 (A100B6008V).

Start fitting the seal from the top rear corner, and ensure that the whole length of the 'u' section is pressed

fully on to the body flange. Remove the backing tape and position the lower section against the sill. use a

roller wheel to ensure full adhesion.

Secondary door seal

In order to minimise wind noise transmitted into the cabin, a secondary seal is fitted along the cant rail and

down the 'A' post. This self adhesive, hollow section rubber extrusion, should be contacted by the door glass

in its fully raised position (see BV.11).

Lotus Service Notes

Section BV

BV.11 - DOOR WINDOW, GuIDE RAILS & LIFT MECHANISM

WARNING: To ease door closure, and optimise the sealing of the frameless door glass against the

weatherstrips, the control mechanism will automatically drop a fully closed window a small distance

when the door is opened (preparatory to closing), and raise it again after the door is shut. This func-

tion may be triggered, with ignition on or off, by door latching signals. Whenever working on or near

the window mechanism, disconnect the window motor to prevent injury from unexpected operation.

Each door uses a single, 4mm thick, green tinted, tempered glass, curved door window, with a frameless

configuration, and an electrically operated lift mechanism. The glass is guided by a pair of curved steel 'L' sec-

tion channels, to which it is constrained by two pairs of point contact Nylon guide blocks bonded to the front and

rear edges of the glass. The lower end of each of the guide rails is adjustable in/out via a screw mechanism,

to enable the correct weatherstrip seal loading to be achieved, whilst the glass upward travel is limited by an

adjustable stop on the lift mechanism.

The lift mechanism uses a top hat section steel lift channel, curved to match the window guide rails, and

attached to the door shell. An alloy carriage plate, clamped to the bottom of the glass, uses a plastic shoe to

slide along one edge of the lift channel. A multistrand steel cable is attached to the carriage plate and is routed

around a pulley at the top and bottom of the lift channel and then around a drum driven by an electric motor.

The assembly thus described is secured at 3 points to the door shell.

A micro-switch mounted on the lift mechanism closes when the glass is fully raised, and triggers the window

automatic drop function when the door is opened.

Viewed From Outboard

Glass

Guide rail

Upstop adjuster

Plastic shoe

Guide rail

upper fixing

Glass clamp

Carriage plate

Cable winder

drum

Guide rail

b361

Window lift Lift channel adjuster

motor assembly

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