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Lotus Eleven/Elise/Exige. Manual - part 15

Lotus Service Notes Section BR

Page 1

BODY FITTINGS

SECTION BR

Sub-Section Page

Removable Roof

BR.1

Rear Window Shroud (Elise only)

BR.2

Front Body Access Panels

BR.3

Engine Cover Lid

BR.4

Door Hinge Cover Panel

BR.5

Front Clamshell

BR.6

Rear Clamshell

BR.7

Door Mirrors

BR.8

Door Shell Brackets

BR.8a

Door Beam & Hinge

BR.9

Door Shell Assembly

BR.10

Door Glass, Guide Rails & Winder Mechanism

BR.11

Electric Windows

BR.12

Door Seals

BR.13

Door Latch Mechanism (without CDL)

BR.14

Central Door Locking

BR.15

Instrument Binnacle & Dash Panel

BR.16

Windscreen

BR.17

Lotus Service Notes Section BR

Page 2

BR.1 - REMOVABLE ROOF

The Lotus Elise has been designed to exploit the pleasures of open top motoring, the better to enjoy

exposure to the natural environment, unencumbered by the restrictions and confinement bestowed by a cock-
pit roof. In order to provide some weather protection to the occupants and vehicle interior, and allow the
continued enjoyment of the car in unfavourable weather conditions, a simple hard or soft top roof may be fitted.

Due to the constantly changing dynamic and wind pressure loadings to which the roof structure is subject

when driving, and the tolerances required to allow for repeated removal and refitting of the roof, complete
weather sealing of the roof cannot be guaranteed, such that some wind noise and minor water leaks are
considered normal for this model. The Elise or Exige should not be subjected to an automatic car wash. Such
machines can induce water leaks caused by high pressure water jets which are not representative of conditions
encountered during normal use. The brushes used may also damage the fabric of the soft top roof.

Exige Hardtop Roof:

The Lotus Exige has been conceived and configured as a sports coupé with a removable roof. The

aerodynamic performance of the bodyshell including the front spoiler, rear aerofoil, roof panel and tailgate
have been tuned to provide the optimum handling balance with the roof scoop on supercharged cars providing
the cooling airflow for the chargecooler.

The roof panel may be removed for better access to the interior for servicing, and the car may be driven

without the roof fitted, but wind buffeting and increased noise levels will be experienced together with a slight
decrease in maximum power on supercharged cars.

Soft Top Roof

A hollow composite roof siderail is used on each side of the car to bridge each top corner of the wind-

screen frame to the roll over bar, and provide a mounting for a weatherstip seal, against which the top edge of
the door glass abuts. The soft top roof canopy is fixed to each siderail, which uses a spigot pin at the front and
rear to engage with a slot in a latch plate on the header rail and roll over bar. A second, spring loaded spigot pin
at each end of the siderails, is arranged to slide into a ramped hole on the latch plates and secure and tension
the soft top via steel cables running through the front and rear of the roof canopy.

Soft Top - Fitting

WARNING: The soft top roof should be fitted only whilst the vehicle is safely parked.

From its stowage bag in the rear luggage
compartment, withdraw the roof assembly
and support stays. Lower both door win-
dows, or open both doors.

Insert the two, identical, roof support stays,
with the arrows pointing forwards, into the
slots above the rear window, and in the wind-
screen header rail. Note that the slots are
keyed to prevent the stays being fitted the
wrong way round.

Lay the soft top roof across the centre of
the roof space with the arrows on the side
rails pointing forwards.

FITTING ROOF STAYS

Arrows
point forward

Rear end keyway

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Lotus Service Notes Section BR

Page 3

Roll out the left hand side of the roof, and
engage the fixed spigot pin on the front and
rear end of the rail, into the uppermost slot
in the latch blocks at the front and rear of
the roof aperture.

Ensure that the tensioning cables at the front
and rear edges of the roof canopy are cor-
rectly located in the channels between the
seal and body before rotating the left hand
side rail downwards.
Ensure that both spring loaded pins ‘click’
into their ramped slots indicating that latch-
ing is complete. If necessary, ease the latch
handles on the inside face of the side rails
inwards to facilitate latching. Pull up on the
side rail to check security.

On the right hand side of the car, repeat steps (4) and (5) for the second side rail, noting that greater
rotating force will be required as tension is applied to the canopy.
Note: Engaging the left hand roof side rail first, will minimise the possibility of the canopy tensioning
cable adjusters causing damage to the roof seals.

Soft Top - Removal

WARNING: The soft top roof should be removed only whilst the vehicle is safely parked.

Open both doors or lower both door win-
dows.

On the inside face of the right hand roof
side rail, locate the two latch release levers:
Pull the two lever handles towards each
other to release the side rail latches (press
down on the side rail if necessary to relieve
the load on the latch pins), and rotate the
rail upwards to release the canopy tension.

Repeat step (2) for the left hand side rail.
Note: Releasing the right hand roof side
rail first, will minimise the possibility of the
canopy tensioning cable adjusters causing
damage to the roof seals.

Carefully roll up each side of the roof canopy towards the centre, lift off the car, and stow in the roof bag.

Unhook the two roof stays and stow in the roof bag.

Important Note: If the roof is not fully dry, it should be stowed for no longer than a few days before unrolling
or refitting and allowing to air dry completely. Prolonged stowage of a wet or damp roof will promote rotting of
the fabric.

Roof Cable - Front: The tension of the steel cable running through the front edge of the roof canopy should be
adjusted with the side rails latched. Hook a spring balance under the centre of the cable, and apply an upwards
force of 6 kgf. Adjust the cable tension to achieve a vertical gap of 6mm between the cable and top surface of
the windscreen surround.

Spigot
pin

Spring
loaded
pin

FITTING SIDERAIL

ohs111

RELEASING ROOF SIDE RAIL

ohs112

Lotus Service Notes Section BR

Page 4

Roof Cable - Rear: The roof rear cable tension should be sufficient only to maintain stability of the roof canopy
shape.
Side Rail Front Latch Plates: The latch plates on the windscreen header rail are secured using a two part
adhesive. If necessary, use Betaclean 3900 (A100B6008V), Betaprime 5404 (A082B6337V), and a 50/50 mix
of two part adhesive Betamate 7064S (A116B0159V) and Betamate 7014 (A116B0158V) to refix.

Hard Top Roof
Note
-

The hard top roof has been designed to provide a seasonal, rather than single trip option. Some owners
may prefer to entrust the fitting and removal of the hard top roof to their dealer.

When stowing the roof off the car, care should be taken to avoid damage to the roof corners; e.g. use a
suitable soft floor covering on which to stand the roof.

Fitment or removal of the hardtop is made considerably easier with the assistance of a second person.

Use only the ‘Torx’ tool supplied in the vehicle tool kit to tighten or release the roof fixing screws.

The hardtop roof fixings are made captive to the roof to prevent their loss.

Hard Top - Fitting
WARNING: The hard top roof should be fitted only whilst the vehicle is safely parked.

Open both doors, and preferably with the

aid of an assistant, lower the roof onto the car
holding aside the loose tethered fixings to avoid
their entrapment or their causing paint damage.
Position the rear edge of the roof first before lo-
cating the front edge against the windscreen
header rail.

Locate a front spigot bracket into its latch

plate lower slot (lifting the roof slightly to allow
this) and retain to the roof with the Torx bolt. Use
only the special tool supplied, and do not fully
tighten at this stage.

Repeat step (2) for the opposite front spigot

bracket.

Engage a rear cup bracket with the lower

tongue on its rear latch plate, and retain to the
roof with the Torx bolt. Use only the special tool
supplied, and do not fully tighten at this stage.
Ensure that the cup is fully located onto the
tongue.

Repeat step (4) for the opposite rear cup

bracket.

Push the roof fully forwards before tighten-

ing the front spigot brackets using only the spe-
cial tool supplied. Hold each rear cup bracket in
alignment whilst tightening the single fixing screw
for each bracket. Do not overtighten.

Fit the cover panels to each rear corner of

the roof, noting that the panels are handed for
left and right sides. Press the panels firmly into
position fully to engage the 'Velcro' fixing patches.

FRONT
SPIGOT
BRACKET

b330

FITTING REAR CUP BRACKET

REAR CORNER
COVER PANEL

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