master cylinder secondary piston NISSAN X-TRAIL 2005 Service Repair Manual

BR-14
BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDERPFP:46010
ComponentsEFS000CB
Removal and InstallationEFS001CG
REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wipe it off immediately and wash it away with water.
1. Drain brake fluid.
2. Remove fluid level sensor harness connector.
3. Using a flare nut wrench, disconnect master cylinder assembly and brake tube.
4. First remove master cylinder assembly mounting nuts. Then remove master cylinder assembly.
INSTALLATION
1. Connect brake tube to master cylinder assembly and temporarily tighten flare nut by hand.
2. Connect master cylinder assembly to brake booster assembly and tighten mounting nuts to the specified
torque.
3. Tighten brake tube flare nuts.
4. Connect fluid level sensor harness connector.
1. Reservoir tank 2. Reservoir cap 3. Oil strainer
4. Pin 5. Cylinder body 6. Piston stopper (Some models with
ABS does not apply.)
7. Grommet 8. O-ring 9. Secondary piston assembly
10. Primary piston assembly 11. Snap ring 12. Guide assembly
13. Plate 14. Stopper cap 15. Primary piston assembly
16. Secondary piston assembly
SFIA1800E
: 15 - 17 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

BRAKE MASTER CYLINDER
BR-15
C
D
E
G
H
I
J
K
L
MA
B
BR

5. Refill with new brake fluid and bleed air from the brake piping.
Disassembly and AssemblyEFS001CH
MODELS WITHOUT ESP (PISTON STOPPER APPLIED.)
Disassembly
CAUTION:
Remove master cylinder reservoir tank only when necessary.
1. Using a slotted flat-bladed screwdriver as shown in the figure,
lever up stopper cap tabs and remove stopper cap. While
removing, be sure to hold cap securely to prevent the master
cylinder piston from popping out.
2. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:

Secure cylinder body flange with chamfered pin insert
hole, facing upward.

When securing in the vise, use copper plates or cloth to
protect the flange.
3. Using a pin punch [tool: diameter Approx. 4 mm (0.16 in)],
remove reservoir tank mounting pins.
4. Remove master cylinder assembly from the vise.
5. Remove reservoir tank and grommet from the cylinder body.
6. Using a Phillips flat-bladed screwdriver, press and hold piston
pin as shown in the figure. Remove piston stopper from the cyl-
inder body.
7. Carefully pull primary piston assembly straight out to prevent
damage to the cylinder inner wall.
8. Tap flange against a wood block to loosen secondary piston
assembly. Carefully pull secondary piston assembly straight out
to prevent damage to the cylinder inner wall.
Inspection After Disassembly

Check cylinder inner wall for damage, wear, corrosion, and pinholes. Replace cylinder if damage, wear, or
corrosion is detected.
BRA0533D
BRA0588D
SFIA0342E
BRA0590D

BR-16
BRAKE MASTER CYLINDER

Assembly
CAUTION:

Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.

Be sure there is no foreign material on the cylinder inner wall, piston, and cup seal. Be careful not
to damage parts with a service tool during assembly.

Do not drop the parts. Do not use any dropped parts.
1. Apply brake fluid to the inner wall of cylinder body and contact
surface of piston assembly. Then insert secondary piston
assembly and primary piston assembly into the cylinder body in
this order.
CAUTION:

Do not reuse primary and secondary piston assemblies.

Always replace primary and secondary piston assemblies
as kit.

Pay attention to orientation of the piston cup. Insert it
straight in order to prevent the cups from catching between
the cylinder's inner wall and piston.
2. Visually check secondary piston slit position through cylinder
body secondary tank boss hole and install piston stopper.
3. Hold piston with stopper cap. Press stopper cap in until its tabs
fully engage groove on the cylinder body.
CAUTION:
Do not reuse stopper cap.
4. Apply brake fluid to grommet before pressing it into cylinder
body.
CAUTION:
Do not reuse grommet.
5. Secure cylinder body flange in a vise as shown in the figure.
CAUTION:

Secure cylinder body flange with chamfered pin insert hole
facing upward.

When securing in the vise, use copper plates or cloth to
protect the flange.
6. Install reservoir tank to cylinder body. Tilt reservoir tank as
shown in the figure to the extent that the mounting pin can be
inserted and insert mounting pin. When mounting pin passes
through pinhole in master cylinder, return reservoir tank to the
upright position. Push mounting pin all the way through the
opposite pinhole in the reservoir tank.
SFIA0248E
BRA0590D
BRA0535D
SFIA0343E

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

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