Lotus Evora, Service Notes

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Page 11
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).