Nissan March K13. Manual - part 38

BRAKE MASTER CYLINDER

BR-25

< REMOVAL AND INSTALLATION >

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BRAKE MASTER CYLINDER

Exploded View

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Removal and Installation

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REMOVAL 

CAUTION:

• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it

off immediately and wash with water if it gets on a painted surface.

• Depress the brake pedal several times to release the vacuum pressure from the brake booster. Then

remove the master cylinder assembly.

1.

Drain brake fluid. Refer to 

BR-9, "Draining"

.

2.

Disconnect the brake fluid level switch harness connector.

3.

Remove the brake tube from between dual proportioning valve and master cylinder assembly with a flare
nut wrench.

CAUTION:

Never scratch the flare nut and the brake tube.

4.

Remove the master cylinder assembly.

CAUTION:

• Never deform or bend the brake tubes.
• Never depress the brake pedal after the master cylinder assembly is removed.

1.

Reservoir cap

2.

Oil strainer

3.

Reservoir tank

4.

Pin

5.

Grommet

6.

Cylinder body

7.

O-ring

: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.

: Apply brake fluid.

Refer to 

GI-4, "Components"

 for symbols not described on the above.

JPFIA0760GB

BR-26

< REMOVAL AND INSTALLATION >

BRAKE MASTER CYLINDER

• The piston of the master cylinder assembly is exposed. Never damage it when removing the

master cylinder.

• The piston may drop off when pulled out strongly. Never hold the piston. Hold the cylinder body

when handling the master cylinder assembly.

INSTALLATION

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.
Note the following, and install in the reverse order of removal.
• Never reuse the O-ring.
• Never depress the brake pedal after the master cylinder assembly is removed.
• Apply silicone grease to the brake booster [see (A) in the figure]

when installing the master cylinder assembly to the brake booster.

• The piston of the master cylinder assembly is exposed. Never

damage it when handling the master cylinder and check that no dirt
and dust are present on the piston before installation. Clean it with
new brake fluid if necessary.

• The piston may drop off when pulled strongly. Never hold the pis-

ton. Hold the cylinder body when handling the master cylinder
assembly.

• Never deform or bend the brake tubes.
• Temporarily tighten the brake tube flare nut to the master cylinder

assembly by hand. Then tighten it to the specified torque with a
flare nut flare nut torque wrench. Refer to 

BR-18, "FRONT : Exploded View"

.

CAUTION:

Never scratch the flare nut and the brake tube.

• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
• After installation, perform the air bleeding. Refer to 

BR-10, "Bleeding Brake System"

CAUTION:

Never reuse drained brake fluid.

• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to 

BR-7,

"Inspection and Adjustment"

.

Disassembly and Assembly

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DISASSEMBLY

CAUTION:

• Never disassemble the cylinder body.
• Remove the reservoir tank only when necessary.
• Never drop the removed parts. The parts must not be reused if they are dropped.

1.

Fix the master cylinder assembly to a vise.

CAUTION:

• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
• Never overtighten the vise.

2.

Remove the reservoir tank mounting pin with a pin punch [4 mm (0.157 in)].

3.

Remove master cylinder from vise.

4.

Remove the reservoir tank and grommet from the cylinder body.

ASSEMBLY

CAUTION:

• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and

assembly process.

• Never drop the when installing. The parts must not be reused if they are dropped.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.

1.

Apply new brake fluid to the grommet and install it to the cylinder body.

CAUTION:

Never reuse the grommets.

2.

Install the reservoir tank to the cylinder body.

3.

Fix the cylinder body to a vise.

JPFIA0013ZZ

BRAKE MASTER CYLINDER

BR-27

< REMOVAL AND INSTALLATION >

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CAUTION:

• Place the reservoir tank with the chamfered pin hole facing up.
• Always set copper plates or cloth between vise grips when fixing the cylinder body to a vise.
• Never overtighten the vise.

4.

Tilt the reservoir tank so that a mounting pin can be inserted. Insert a mounting pin. Return the reservoir
tank to the horizontal position. Insert another mounting pin into the pin hole on the opposite side in the
same manner after the mounting pin passes through the cylinder body pin hole.

CAUTION:

Never reuse the mounting pin.

Inspection

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INSPECTION BEFORE REMOVAL

Check the brake fluid level switch. Refer to 

BRC-4, "Component Inspection"

.

INSPECTION AFTER INSTALLATION

Check the following items and replace if necessary.
• Check the master cylinder for deformation, twist, contact with other parts or looseness of connection.
• Check for fluid leakage from connection. Refer to 

BR-19, "FRONT : Inspection"

.

CAUTION:

If the fluid leakage is present, retighten to the specified torque. Replace if necessary.

BR-28

< REMOVAL AND INSTALLATION >

BRAKE BOOSTER

BRAKE BOOSTER

Exploded View

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Removal and installation

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REMOVAL

CAUTION:

Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with water if it gets on a painted surface.

1.

Drain brake fluid. Refer to 

BR-9, "Draining"

.

2.

Remove brake master cylinder assembly. Refer to 

BR-25, "Removal and Installation"

.

3.

Remove vacuum hose from brake booster. Refer to 

BR-31, "Removal and Installation"

.

4.

Remove intake manifold. Refer to 

EM-30, "WITH EGR CONTROL VALVE : Removal and Installation"

.

5.

Remove low-pressure flexible hose. Refer to 

HA-34, "LOW-PRESSURE FLEXIBLE HOSE : Removal and

Installation"

.

6.

Separate brake tube from dual prpportioning valve and front RH brake hose (dual proportioning valve side
only).

7.

Remove snap pin (1) and clevis pin (2). Refer to 

BR-16,

"Exploded View"

.

8.

Remove nuts on brake booster and brake pedal assembly. Refer
to 

BR-16, "Exploded View"

.

9.

Remove engine mounting bracket and rear torque rod, and slid
the engine forward with a jack.

10. Remove brake booster from dash panel in engine room side.

CAUTION:

Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster.

INSTALLATION

CAUTION:

1.

Master cylinder assembly

2.

Brake booster

3.

Lock nut

4.

Clevis

5.

Gasket

Refer to 

GI-4, "Components"

 for symbols in the figure.

JPFIA0761GB

JPFIA0019ZZ