Lotus 2004 ELISE Service Notes page 58

Lotus Service Notes
Rubber bung
Rotor bush
Plastic bearing
Door beam/
hinge rotor
Stator bracket
Cap head screw
Hinge bracket
fixings
BR.10 - DOOR SHELL ASSEMBLY
The door shell is mounted on the door beam via three screws through a flange at the front end of the
beam, and by the door latch mounting bracket at the rear end. In order to provide fixing points for the beam,
lock mechanism and other components, the door shell includes various tapping plates and brackets jig bonded
to the inside of the shell, including fixing brackets for the accurate location of the window guide rails.
If a door is to be removed from the car, the preferred method is to release the M10 cap head screws
clamping the upper and lower bushes to the door beam. The beam and door shell assembly may then be
withdrawn from the hinge stator bracket without losing adjustment of the hinge alignment and door shutlines. If
the door shell has to be removed from the beam for repairs or replacement, the beam may be left 'in situ' and
the door shell slid off the beam using the following procedure:
Removal of door shell from beam
The door shell is secured to the beam via three screws through a flange at the front end of the beam,
tapping into nut plates bonded into the door shell, and via two bolts at the rear end of the door to the door beam
extension bracket. Access to the two bolts securing the extension bracket to the door beam requires that the
door glass first be released:
1. Remove the window winder handle and door trim panel (manual windows) or the door trim panel and
window switch (electric windows).
2. Release the three screws securing the interior release handle, and unclip the control rod from the mecha-
nism.
3. Remove the two M6 and the single M8 screw securing the door beam flange to the front of the door shell
4. Release the three M6 nuts securing the door glass to the lift channel, and separate the glass from the
channel. Tilt the glass as necessary to allow access to the two M8 bolts fixing the rear end of the door
beam to the extension bracket. Remove the bolts and withdraw the door assembly from the beam.
Note that it is necessary to remove the drop glass waist seal before the glass may be withdrawn from the
door.
Section BR
b244
Page 15