Lotus 2004 ELISE Service Notes page 412

Lotus Service Notes
To replace the slave cylinder:
- Clean the slave cylinder and surrounding area with methylated spirit. Do not use petrol or paraffin.
- Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
- Unscrew the pipe union nut from the slave cylinder and drain the hydraulic fluid into a suitable container.
Cap both pipe and cylinder port to limit fluid loss and prevent dirt ingress.
- Remove the two cylinder retaining bolts and withdraw the cylinder and pushrod assembly.
- Remove the cylinder boot and pushrod.
- Tap the cylinder or use a low pressure airline to remove the piston and spring from the cylinder.
CAUTION - Use a workshop towel to protect against hydraulic fluid spray, and protect painted
surfaces from contamination.
- Thoroughly clean the cylinder bore using hydraulic fluid. If any scoring, corrosion, damage or wear is
evident, the cylinder assembly should be renewed.
- When refitting the piston and spring, use Lithium soap based glycol grease on the piston and seal before
carefully inserting the spring and piston into the cylinder.
- Fit the pushrod into the boot and the boot to the cylinder.
- Fit the cylinder with the tie wrap bracket to the clutch housing, and torque the two fixing bolts to 12 Nm.
- Fit the hydraulic pipe to the slave cylinder and torque to 15 Nm.
- Bleed the hydraulic system and tighten the bleed nipple to 8.4 Nm.
Bleed nipple
Fixing bolts
Hydraulic Pipe
A rigid steel pipe is used to convey the hydraulic fluid from the master cylinder to the left hand front corner
of the engine bay. The pipe is routed through the dash baffle panel and down the LH 'A' post to run along the
outside of the chassis LH main siderail, within the composite sill member, clipped to the heater pipe. The pipe
terminates at a bracket rivetted to the rear end of the chassis siderail, where it connects to a flexible hose
secured at its other end to a bracket on the clutch housing. A short steel pipe links this joint to the clutch slave
cylinder, which uses a 'quickfit' push-in connector to aid production line assembly.
Slave cylinder
Tie wrap bracket
Spring
Piston
Section QH
Pushrod
Boot
q53
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