Nissan Frontier D22. Manual — part 162
MASTER CYLINDER
BR-15
C
D
E
G
H
I
J
K
L
M
A
B
BR
INSTALLATION
CAUTION:
●
Refill with new brake fluid “DOT 3”.
●
Never reuse drained brake fluid.
1.
Place master cylinder onto brake booster and secure master
cylinder nuts lightly.
2.
Tighten master cylinder nuts.
3.
Fill reservoir tank with new brake fluid.
4.
Plug all ports on master cylinder with fingers to prevent air suc-
tion while releasing brake pedal.
5.
Have driver depress brake pedal slowly several times until no air comes out of master cylinder.
6.
Fit brake lines to master cylinder.
7.
Tighten flare nuts.
8.
Bleed air from brake system. Refer to
BR-10, "Bleeding Brake System"
Disassembly and Assembly
EFS003FM
DISASSEMBLY
2WD Models and 4WD models with MT
1.
If necessary, remove pressure sensor (4WD models with AT and VDC) or pressure switch (2WD models
and 4WD models with MT).
2.
If necessary, remove brake fluid level switch.
3.
Bend claws of stopper cap outward.
4.
Remove piston assemblies.
NOTE:
If it is difficult to remove secondary piston assembly, gradually
apply compressed air through fluid outlet.
5.
Draw out reservoir tank.
4WD models with AT and VDC
CAUTION:
Be careful not to damage the rod of the primary piston with covering cloths.
Master cylin-
der nuts
: 12 - 15 N·m (1.2 - 1.5 kg-m, 9 - 11 ft-lb)
Flare nuts
: 17 - 22 N·m (1.7 - 2.2 kg-m, 13 - 16 ft-lb)
ABR190
SBR938A
SBR939A
BR-16
MASTER CYLINDER
1.
Tighten the cylinder body flange in a vise as shown.
CAUTION:
●
Pay attention to the orientation of the master cylinder
body.
●
Use a copper plate to protect the body in the vise.
2.
Remove pin from the reservoir tank using suitable tool.
3.
Remove the master cylinder assembly from the vise.
4.
Remove the reservoir tank and grommet from the cylinder body.
5.
Push the primary piston and remove the stopper pin form sec-
ondary tank boss hole in the cylinder body.
CAUTION:
Be careful not to damage the inner wall of the cylinder.
6.
Press in the primary piston and remove the snap ring.
7.
Holding the rod of the primary piston, remove the primary piston
assembly, the plate and the guide. Pull components straight out
of the cylinder to prevent damage to the inner wall of the cylin-
der.
8.
Remove the plate and guide from the primary piston.
CAUTION:
Be careful not to damage the rod on the inner wall of the
plate.
INSPECTION AFTER DISASSEMBLY
Master cylinder
Check master cylinder inner wall for pin holes and scratches. Replace if damaged.
Piston
Check the piston cup for damage. Replace the piston if damage is found.
ASSEMBLY
CAUTION:
●
Never use mineral oils such as kerosene or gasoline during the cleaning and assembly process.
●
Make sure there is no foreign material such as dirt and dust on the inner cylinder wall, piston and
cup seal.
BRA0558D
BRA0559D
BRA0560D
BRA0561D
MASTER CYLINDER
BR-17
C
D
E
G
H
I
J
K
L
M
A
B
BR
●
Be careful not to damage the parts with a service tool when assembling.
●
Do not drop parts. Do not use dropped parts.
2WD Models and 4WD models with MT
1.
Insert secondary piston assembly. Then insert primary piston
assembly.
CAUTION:
Pay attention to direction of piston cups in figure. Also,
insert pistons squarely to avoid scratches on cylinder bore.
2.
Install stopper cap.
NOTE:
Before installing stopper cap, ensure that claws are bent inward.
3.
Push reservoir tank seals into cylinder body.
4.
Push reservoir tank into cylinder body.
5.
If necessary, install pressure switch (2WD models).
6.
If necessary, install brake fluid level switch.
4WD models with AT and VDC
1.
Apply brake fluid to the inner wall of the cylinder body and contact surface of the piston assembly.
2.
Insert secondary piston and primary piston assembly in the cylinder body.
CAUTION:
●
Pay attention to direction of piston cups. Also, insert pistons squarely to avoid scratches on
cylinder bore.
●
Always replace the inner kit as an assembly.
3.
Align the slit in the center of the piston with the axial direction of
the valve stopper. Visually check the secondary piston slit from
the valve stopper mounting hole and install the valve stopper.
CAUTION:
Always replace the piston pin O-ring with a new one in the
repair kit.
4.
Insert the plates and the guide into the cylinder body as shown.
CAUTION:
●
Be careful not to damage the primary piston rod.
●
Pay attention to the orientation of the guide
WFIA0081E
Pressure switch
: 7.91 - 11.30 N·m (0.8 - 1.2
kg-m, 6 - 9 ft-lb)
SBR940A
BRA0560D
SFIA0701E
BR-18
MASTER CYLINDER
5.
Press in the primary piston and install a new snap ring.
CAUTION:
●
Make sure snap ring is fully inserted in the snap ring
groove.
●
Do not reuse snap ring.
6.
Tighten the cylinder body flange in a vise as shown.
CAUTION:
●
Pay attention to the orientation of the master cylinder body.
●
Use a copper plate to protect the body in the vise.
7.
Apply brake fluid to new grommets and install them into the master cylinder.
CAUTION:
Do not reuse grommets.
8.
Install a new reservoir tank to the master cylinder.
CAUTION:
●
Pay attention to the orientation of the reservoir tank.
●
Do not reuse reservoir tank.
9.
Install spring pin to hold reservoir tank to cylinder body.
10. If necessary, install pressure sensor.
11. If necessary, install brake fluid level switch.
BRA0561D
BRA0568D
Pressure sensor
: 25 - 30 N·m (2.0 - 3.1 kg-m,
15 - 23 ft-lb)
SFIA0702E
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