Brake Callipers; Brake Master Cylinder; Rear Disc Replacement - Lotus Evora Service Notes

Lotus Service Notes
2. Remove the two bolts securing the brake calliper to the hub carrier, and withdraw the calliper from the
disc. Secure clear without straining the flexible hose.
3. Remove the single countersunk screw, and withdraw the disc from the hub.
4. Before re-fitting a disc, ensure that the mating face between disc and hub is scrupulously clean. Mount
the correctly handed disc (with the curved vanes trailing in normal direction of rotation) onto the hub spigot,
align the fixing screw hole, and secure the disc with the screw, tightening to 10 Nm.
5. Apply Permabond A130 (Blue - A912E7033) to the threads of the calliper fixing bolts. Fit the calliper with
pads over the disc and secure to the hub carrier with the two bolts. Tighten to 86 Nm.
6. Refit the road wheel and when all brakes are assembled, pump the brake pedal to restore brake pad posi-
tion before driving the car.

Rear Disc Replacement

Replacement of the rear discs is similar to that for the front discs, except that the adjuster for the parking
brake shoes should first be slackened to allow easy withdrawal of the disc/drum. Re-adjust after re-assem-
bly.
JL.7 - BRAKE CALLIPERS
The brake callipers are supplied by A.P. Racing, and feature lightweight alloy bodies housing four pistons
in opposed pairs. The castings for the front and rear callipers are common, but are machined differently to
accommodate the differing piston diameters. In the front callipers, the leading pistons are 38.1 mm diameter,
and the trailing pistons 41.3 mm. The rear callipers house 38.2 mm leading pistons and 36.0 mm trailing. Each
calliper is marked on its inner, inboard face, alongside the pad aperture, with its designated fitting position; 'RF'
representing Right hand Front, with others marked as LF, RR, and LR.
Each calliper is secured to its hub carrier by two bolts disposed in a plane perpendicular to the disc axis,
with the front callipers mounted behind the axle line, and the rear callipers ahead of the axle.
The brake callipers are to be dismantled or overhauled only A.P. Racing at Wheeler Road, Seven Stars
Industrial Estate, Coventry, CV3 4LB.
Front calliper fixing bolt torque; 86 Nm using Permabond A130.
Banjo bolt, flexi hose to calliper; 20 Nm.
Flexi hose to subframe bracket; 16 Nm.
JL.8 - BRAKE MASTER CYLINDER
The Continental Teves tandem master cylinder incorporates a rear section to supply both front brakes,
and a front section to supply the rear brakes. A translucent fluid reservoir is mounted on a bracket above the
master cylinder, and is divided into front and rear chambers separated by a weir. The two chambers are con-
nected to the front and rear master cylinder sections by flexible hose, with a third hose connecting the rear
brake reservoir chamber to the clutch master cylinder to supply that system's needs. A fluid level sensor in the
filler cap will light a fascia tell tale lamp if the level becomes dangerously low.
The master cylinder is secured to the front face of the brake servo which itself is bolted to the front of the
pedal box. Access is available only after removal of the front clamshell. The master cylinder manufacturer
does not recommend any dismantling of the unit, and supplies no replacement parts or internal components.
If the cylinder is faulty it should be renewed as a complete assembly.
To remove the unit, proceed as follows:
1. Remove the front clamshell (see Sub-section BV.4) and radiator air outlet duct.
2. Syphon fluid from the reservoir to reduce spillage. Release the two hoses connecting the master cylinder
to the fluid reservoir, and plug the hoses. Disconnect the electrical cables from the reservoir cap.
3. Release the two brake pipes from the master cylinder, and plug the pipes and ports.
Section JL
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