NISSAN X-TRAIL 2003 Service Repair Manual

BRAKE MASTER CYLINDER
BR-17
C
D
E
G
H
I
J
K
L
MA
B
BR

CAUTION:

Do not reuse reservoir tank mounting pin.

Do not reuse reservoir tank.

Be sure to insert pin from the chamfered pinhole on the cylinder body.
MODELS WITHOUT ESP (PISTON STOPPER NOT APPLIED.)
CAUTION:
Remove reservoir tank only when absolutely necessary.
Disassembly (Piston Assembly)
1. Using a flat-bladed screwdriver as shown in the figure, lift up the
tabs on the stopper cap and remove it from the master cylinder.
NOTE:
Remove stopper cap while holding it because the piston in mas-
ter cylinder may pop out.
2. Carefully pull primary piston assembly straight out to prevent the
cylinder inner wall from being damaged.
3. Tap flange using a soft block, such as wood, and carefully pull
secondary piston assembly straight out to prevent cylinder body
inner wall from being damaged.
Inspection After Disassembly (Piston Assembly)
Cylinder body

Check inner wall of cylinder for damage, abrasion, corrosion, and pinholes. Replace the cylinder body if
detected.
Assembly (Piston Assembly)
CAUTION:

Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.

Make sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, the
piston, or the cap seal, and use care to avoid damaging parts with the assembly tools.

Do not drop parts. If a part is dropped, do not use it.
1. Apply fluid to cylinder inner wall body and contact surface of the
piston assembly. Then insert secondary piston assembly and
primary piston assembly into cylinder body in this order.
CAUTION:

Pay attention to the orientation of the piston cup, and
insert straight to prevent the cup from being caught by
cylinder inner wall.

Be sure to replace the assembly without disassembling
the new inner kit.

Do not reuse the primary and secondary piston assem-
blies.
BRA0031D
BRA0033D
SFIA2051E

BR-18
BRAKE MASTER CYLINDER

2. Holding down the piston with the stopper cap, push the stopper
cap tabs so they are firmly into the cylinder grooves, then attach
the stopper cap.
CAUTION:
Do not reuse the stopper cap.
Disassembly (Reservoir Tank)
1. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting the master cylinder assembly in a vise, be
sure not to over-tighten.

When securing in a vise use copper plates or cloth to
protect the flange.
2. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pins on the reservoir
tank.
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.
Assembly (Reservoir Tank)
1. Apply brake fluid or rubber lubricant to a grommet, and then install it into cylinder body after installing
grommet to reservoir tank.
CAUTION:
Do not reuse the reservoir tank and grommet.
2. Secure master cylinder assembly into a vise with the chamfered
pin insert hole on cylinder body facing upward.
CAUTION:

When setting the master cylinder assembly in a vise, be
sure not to over-tighten.

When securing in a vise use copper plates or cloth to
protect the flange.
BRA0035D
BRA0588D
SFIA0342E
BRA0588D

BRAKE MASTER CYLINDER
BR-19
C
D
E
G
H
I
J
K
L
MA
B
BR

3. Tilt reservoir tank as shown in the figure for the mounting pin to
be inserted. Return the reservoir tank to the upright position
when mounting pin passes through pinhole in the cylinder body.
Push mounting pin to the opposite pinhole of the reservoir tank,
so that it is the same condition as the insertion side.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse the mounting pin.
MODELS WITH ESP
Disassembly
CAUTION:

While working, cover primary piston rod with cloth to prevent it from being damaged.

Only remove reservoir tank when absolutely necessary.
1. Place the side of cylinder body with chamfering around the pin
insertion hole up, and secure the cylinder body flange section
with a vise as shown in the figure.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect flange.
2. Using a pin punch [commercial service tool: approximately 4
mm (0.16 in) dia.], remove reservoir tank mounting pin.
3. Remove master cylinder assembly from the vise.
4. Remove reservoir tank and grommet from cylinder body.
5. Push in the primary piston and remove stopper pin from the cyl-
inder body secondary-side tank boss hole.
SFIA0342E
BRA0558D
BRA0559D
BRA0560D

BR-20
BRAKE MASTER CYLINDER

6. Remove the snap ring while pushing primary piston in to prevent
piston from popping out.
7. Holding primary piston rod, pull primary piston assembly, plate,
and guide straight out.
8. Remove plate and guide from primary piston.
CAUTION:
When removing plate from primary piston rod, make sure
the inside of plate does not damage rod.
9. Tap flange using a soft block such as wood, and carefully pull
the secondary piston assembly straight out to prevent cylinder
inner wall from being damaged.
Inspection After Disassembly
Master cylinder

Make sure there is no damage, friction, rusting, or pinholes on the cylinder inner wall, and replace if there
are any non-standard conditions.
Assembly
CAUTION:

Never use mineral oils such as kerosene, gasoline during the cleaning and assembly process.

Make sure there is no foreign matter such as dirt or dust attached to the inner cylinder walls, pis-
ton, or cap seal, and use care to avoid damaging parts with the assembly tools.

Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the inside surface of cylinder body and the
contact surface of piston assembly, and apply the silicon grease
in the inner kit to primary piston rod.
2. Insert secondary piston and primary piston into cylinder body.
CAUTION:

Do not reuse the primary and secondary piston assem-
blies.

Be sure to replace the assembly without disassembling
new inner kit.

Pay attention to the orientation of piston cup, and insert
straight to prevent cup from being caught by cylinder
inner wall.
BRA0561D
BRA0033D
PFIA0263E

BRAKE MASTER CYLINDER
BR-21
C
D
E
G
H
I
J
K
L
MA
B
BR

3. Visually inspect the secondary piston slit through the piston
stopper mounting hole and then install the piston stopper while
pushing in the primary piston.
4. Insert plate and guide into cylinder body.
CAUTION:

Make sure not to damage primary piston rod.

Pay attention to the orientation of guide assembly.

Do not drop O-ring.

Make sure guide and/or plate are not inserted at an angle.
5. Cover primary piston rod with cloth to prevent it getting dam-
aged, and attach snap ring with primary piston pushed in.
CAUTION:

Make sure the area around snap ring is snug in the cylin-
der body bore groove.

Do not reuse snap ring.
6. Apply brake fluid to grommet and attach reservoir tank to master
cylinder.
CAUTION:
Do not reuse grommet.
NOTE:
Attach reservoir tank in the orientation shown in the figure.
BRA0560D
SFIA1293E
BRA0561D
BRA0568D

BR-22
BRAKE MASTER CYLINDER

7. Place the side of cylinder body with chamfering around the pin
insertion hole up, and secure the cylinder body flange section
with a vise.
CAUTION:
When securing in a vise, use copper plates or cloth to pro-
tect flange.
8. Tilt reservoir tank so that mounting pin can be inserted as shown
in the figure, and insert mounting pin. When mounting pin has
passed the master cylinder pinhole, return reservoir tank to a
level position. Attach mounting pin to the opposite mounting pin
hole of reservoir tank so that it is the same as the insertion side.
CAUTION:

Be sure to insert pin from the chamfered pinhole of cylin-
der body.

Do not reuse reservoir tank and mounting pin.
BRA0558D
SFIA0702E

BRAKE BOOSTER
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR

BRAKE BOOSTERPFP:47200
On-Vehicle Inspection and ServiceEFS000CC
FUNCTION INSPECTION
With engine stopped, discharge stored vacuum by depressing brake
pedal several times at 5 second intervals. With brake pedal fully
depressed, start the engine. Confirm that clearance between brake
pedal and floor panel decreases when engine vacuum stabilizes.
AIRTIGHTNESS INSPECTION

Run engine at idle for approximately 1 minute. Stop it after
applying vacuum to the booster. Depress brake pedal several
times with normal force to discharge the stored vacuum. Con-
firm that clearance between brake pedal and floor panel gradu-
ally increases as the brake pedal is depressed.

Run engine. Depress and hold brake pedal then stop engine.
Keep brake pedal depressed for 30 seconds or more and make
sure the pedal stroke does not change.
Removal and InstallationEFS000CD
REMOVAL
CAUTION:

Be careful not to deform or bend brake piping while remov-
ing and installing brake booster.

Replace clevis pin if it is damaged.

Be careful not to damage brake booster stud bolt threads. If
brake booster is tilted or inclined during installation, dash
panel may damage the threads.

Be sure to install check valve in the correct orientation.
1. Remove vacuum piping from the brake booster.
2. Remove master cylinder.
3. Remove snap pin and clevis pin on the clevis of input rod. Remove input rod from the brake pedal.
4. Remove brake booster and brake pedal assembly mounting nuts.
5. Remove booster assembly from the engine compartment.
BRA0037D
SBR365AA
SFIA0139E

BR-24
BRAKE BOOSTER

INSPECTION AFTER REMOVAL
Output rod length inspection
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length.
3.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to booster assembly.
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-9, "
Bleeding Brake System" . Reference value at vacuum of –66.7 kPa (–500 mmHg,
–19.69 inHg):
Without ESP models : 10.4 mm (0.409 in)
With ESP models : -6.2 mm (-0.244 in)
SBR208E
Length “B” standard : 125 mm (4.92 in)
SGIA0060E

VACUUM LINES
BR-25
C
D
E
G
H
I
J
K
L
MA
B
BR

VACUUM LINESPFP:41920
Removal and InstallationEFS000CE
RHD MODELS
LHD MODELS
CAUTION:

Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.
SFIA2093E
1. Vacuum hose 2. Vacuum tube 3. Clip
4. Clamp
SFIA2094E
1. Vacuum hose 2. Clip 3. Clamp

BR-26
VACUUM LINES


Insert the vacuum hose at least 24 mm (0.94 in).

Never use lubricating oil during assembly.
InspectionEFS000CF
VISUAL INSPECTION
Check for improper assembly, damage and aging.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a hand-held vacuum pump to check.
SBR225B
When connected to booster side (1):
Vacuum decrease should be within 1.3 kPa
(10 mmHg, 0.39 inHg) for 15 seconds under
a vacuum of –66.7 kPa (–500 mmHg, –19.69
inHg)
When connected to engine side (2):
No vacuum will be applied
SFIA0210E