>> There was some thought that one of the seals in the original m/c may have
>> 'flipped' when the g clamp was applied but disassembly proved difficult so couldn't verify.
I was just about to suggest this. Good job I carried on reading the whole thread first. I always opt for slackening off the bleed nipple these days when having to push the piston back into the calliper because of this very reason.
>> I haven't talked in length to the owner since the ebay m/cylinder was installed.
The trouble with 2nd hand parts is you just don't know the history. Did the seller say it guaranteed and tested? Mind you, anyone can say that it has been tested, but actually hasn't been.
Not sure if this helps at all? A diagram of a stripped down master cylinder.
www.99rpm.com/hyundai/brake-master-cylinder-i10.html
www.99rpm.com/media/catalog/product/cache/6/image/b459b361606096bcb3b026720354ac59/b/r/brake_master_cylinder_i10.jpg
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