Lotus Elise Service Notes page 330

D Lotus Service Notes
Section JH
5. Press the stop sleeve against the rear piston and release the screw retaining the sleeve. Remove the
stop sleeve, screw, spring and spring seat washer. Carefully remove the primary seal and grooved seal
from the rear piston.
6. From the front piston, remove the primary seal and the two secondary seals.
7. Thoroughly clean the cylinder bore, inlet and outlet ports, and all component parts using brake cleaning
fluid or alcohol and blow dry with compressed air. Carefully inspect the master cylinder bore for scoring
and corrosion. Any more than the slightest signs of either of these effects indicates that the unit should
be renewed.
8. Thinly coat the cylinder bore with ATE Brake Cylinder Paste or ATE Brake Assembly Spray or a similar
product, to facilitate assembly and prevent corrosion.
9. Before assembling the seals onto the pistons, note that three different seals are used, with the part
number printed on the lip of each seal.
Primary seal 03.3301-1933.1
Secondary seal 0 3 . 3 3 0 1 - 1 9 3 4 . 1
Grooved seal 03.3402-1901.1
Grooved seal
10. Assemble the front piston:
- Fit a primary seal (03.3301-1933.1) into the front groove of the piston with the lip facing forwards.
- Fit the support ring onto the piston nose to retain the seal and form a seat for the cylinder front
spring.
- Fit a pair of secondary seals (03.3301-1934.1) into the two grooves at the rear end of the piston,
with the lip of the front seal facing forwards, and the lip of the rear seal facing rearwards.
11. Assemble the rear piston:
- Fit a grooved seal (03.3402-1901.1) into the rear groove with the lip facing forwards.
- Fit a primary seal (03.3301-1933.1) onto the front of the piston with the lip facing forwards.
- Fit the spring support ring onto the piston spigot, spring and stop sleeve, and compress the spring
to enable the retaining screw to be fitted and tightened.
12. Thinly coat all piston seals and the piston shoulders with ATE Brake Cylinder Paste or ATE Brake
Assembly Spray or similar.
13. Fit the front piston return spring onto its seat on the front piston, and carefully insert the front piston
assembly into the cylinder taking great care not to damage the lips of the forward facing seals.
14. Fit the rear piston assembly into the cylinder, again taking great care not to damage the lips of the
forward facing seals. Using a rounded end drift, press the piston against its spring to enable the
stop washer and retaining circlip to be fitted into the end of the cylinder.
Page 11 1998 / 03