Nissan Juke F15. Manual — part 95
BR-40
< REMOVAL AND INSTALLATION >
BRAKE MASTER CYLINDER
• Temporarily tighten the brake tube flare nut to the master cylinder
assembly by hand. Then tighten it to the specified torque with a
crowfoot and torque wrench (A). Refer to
.
• Perform the air bleeding. Refer to
BR-13, "Bleeding Brake System"
• Perform inspection after installation. Refer to
Disassembly and Assembly
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DISASSEMBLY
CAUTION:
• Never disassemble the master cylinder.
• Remove the reservoir tank only when necessary.
1. Fix the master cylinder assembly to a vise.
CAUTION:
• Always set copper plates or cloth between vise grips when fixing the master cylinder to a vise.
• Never overtighten the vise.
2. Remove the reservoir tank mounting pin with a pin punch (A) [4
mm (0.157 in)].
3. Remove the reservoir tank and grommet from the master cylin-
der.
ASSEMBLY
CAUTION:
• Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and
assembly process.
• Never allow foreign matter (e.g. dust) and oils other than brake fluid to enter the reservoir tank.
• Never drop the when installing. The parts must not be reused if they are dropped.
1. Apply new brake fluid to the grommet and install it to the master cylinder.
CAUTION:
Never reuse the grommets.
2. Install the reservoir tank to the master cylinder.
3. Fix the master cylinder to a vise.
CAUTION:
• Place the reservoir tank with the chamfered pin hole (
)
facing up.
• Always set copper plates or cloth between vise grips
when fixing the master cylinder to a vise.
• Never overtighten the vise.
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BRAKE MASTER CYLINDER
BR-41
< REMOVAL AND INSTALLATION >
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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 master cylinder 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-116, "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
CAUTION:
If the fluid leakage is present, retighten to the specified torque. Replace if necessary.
BR-42
< REMOVAL AND INSTALLATION >
BRAKE BOOSTER
BRAKE BOOSTER
Exploded View
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Removal and installation
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REMOVAL
1. Perform inspection before removal. Refer to
BR-43, "Inspection and Adjustment"
.
2. Remove cowl top and cowl top extension. Refer to
EXT-30, "Removal and Installation"
.
3. Remove air duct and air cleaner case. Refer to
EM-27, "Removal and Installation"
4. Remove brake master cylinder assembly. Refer to
BR-38, "Removal and Installation"
.
5. Remove vacuum hose from brake booster. Refer to
BR-46, "Removal and Installation"
6. Remove snap pin (1) and clevis pin (2). Refer to
7. Remove nuts on brake booster and brake pedal assembly.
CAUTION:
Hold the brake booster so as to avoid dropping out.
8. Remove brake booster and spacer.
CAUTION:
Never deform or bend the brake tubes.
NOTE:
If removing brake booster is difficult, remove clevis from brake
booster.
9. Remove spacer from brake booster.
10. Perform inspection after removal. Refer to
BR-43, "Inspection and Adjustment"
.
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.
• Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installation, the
dash panel may damage the threads.
1.
Master cylinder assembly
2.
Brake booster
3.
Lock nut
4.
Clevis
5.
Gasket
6.
Spacer
: N·m (kg-m, ft-lb)
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BRAKE BOOSTER
BR-43
< REMOVAL AND INSTALLATION >
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• Never deform or bend the brake tubes when installing the brake booster.
• Always use a gasket between the brake booster and the spacer.
• Replace the clevis pin if it is damaged. Refer to
BR-21, "Inspection and Adjustment"
• Perform the air bleeding. Refer to
BR-13, "Bleeding Brake System"
.
• Check each item of brake pedal. Adjust it if the measurement value is not the standard. Refer to
.
Inspection and Adjustment
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INSPECTION BEFORE REMOVAL
Air Tight
CAUTION:
Check the air tight condition when the master cylinder and the brake booster is installed.
1. Check the air tight use a handy vacuum pump.
2. If the air tight condition cannot be maintained, perform the following operation.
a. Check the no dirt and dust are present on the brake booster and brake master cylinder mating faces.
Clean it if necessary.
b. Check the O-ring on the master cylinder. If anything is found, replace the O-ring. Refer to
c. Check the air tight condition again. If the condition still cannot be maintained, replace the brake booster.
INSPECTION AFTER REMOVAL
Input Rod Length Inspection
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).
2. Tighten the lock nut to the specified torque.
INSPECTION AFTER INSTALLATION
Operation
Depress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower panel decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a
normal phenomenon due to the brake system operation.
Air Tight
1. Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.
2. Depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually
increases each time the brake pedal is depressed when performing this operation.
3. Depress the brake pedal with the engine running. Then stop the engine while holding down the brake
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec-
onds or more.
ADJUSTMENT AFTER INSTALLATION
At vacuum of
−66.7 kPa (−500 mmHg,
−19.69 inHg)
: Vacuum should decrease within 3.3 kPa (24.8 mmHg,
0.98 inHg) for 15 seconds.
A
: Refer to
.
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