Lotus TURBO ESPRIT Service Manual page 325

SECTION JC
a
3C. 8
-
MASTER CYLINDER OVERHAUL
Page
9
Disconnect the fluid level switch leads, release the three brake pipes from the
cylinder and remove the two nuts and washers securing the master cylinder to
the servo. Remove the master cylinder assembly from the vehicle to a clean
workplace before further dismantling.
Drain the reservoir and pull out from its two master cylinder grommets.
Push on the primary piston and remove the stop screw from the undenide
of the cylinder, and circlip from the cylinder end.
Withdraw the primary piston assembly
and eject the secondary piston assembly
and spring using compressed air (max
3 bar). Never tap or strike the master
cylinder to remove the piston.
Clean a l l parts with methylated spirit or brake system cleaning fluid and inspect.
If
the master cylinder bore shows any signs whatever of scoring, wear, or corrosion,
the complete unit should be replaced.
Note: The screw securing the return spring to the primary piston
i s
factory set
and must not be disturbed.
Coat both new pistorl assemblies from a master cylinder repair k i t with clean
brake fluid and insert the secondary piston assembly with
i t s
spring into the
cylinder. Use a screwdriver with rounded blade to ease sealing washer entry
into the bore, and a rounded end 3mm diameter brass rod to ease the seals past
the reservoir ports and stop screw h d e .
F i t
the primary piston assembly and
spring i n a similar manner, and retain
i n the cylinder by inserting the brass
rod through the rearmost reservoir
port, whilst pushing on the piston.