Lotus 2004 ELISE Service Notes page 228

Lotus Service Notes
JJ.9 - BRAKE MASTER CYLINDER
The tandem brake master cylinder is mounted in the front compartment and is secured to the brake servo
by two studs with M8 nuts. The cylinder uses two pistons to supply the independent front and rear brake
circuits. The cross-section below is provided for information, but 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.
Key to Cross-Section
1. Body
2. Passage to rear cylinder
3. Rear cylinder inlet port
4. Guide bush
5. Rear piston
6. Lip seal
7. Stop washer
8. Primary seal
9. Washer
To remove the unit, proceed as follows:
1. On Exige models, remove the front clamshell (see sub-section BR.6).
2. Syphon fluid from the reservoir to reduce spillage.
3. Release the two hoses connecting the master cylinder to the fluid reservoir, and the single hose connect-
ing to the clutch master cylinder, and plug all hoses. Disconnect the electrical cables from the reservoir
cap, cut the tie wrap and withdraw the reservoir from the mounting bracket.
4. Release the two brake pipes from the master cylinder, and plug the pipes and ports.
5. Release the two nuts securing the master cylinder to the brake servo and remove the cylinder.
6. Refit the master cylinder in reverse order to removal, using NEW locknuts (supplied with a new cylinder)
and tighten to the following torques:
- Master cylinder fixing nuts; 25 Nm
- Brake pipes to cylinder; 17.5 Nm
7. Fill the reservoir with DOT 4 non-mineral type brake fluid, and bleed the complete brake system of air
using standard vacuum assisted, pressure assisted or manual techniques.
10. Spring plate
11. Retaining screw
12. Stop sleeve
13. Rear piston spring
14. Front piston
15. Secondary seal
16. Transfer passage
17. Front piston stop
18. Front piston spring
Section JJ
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