NOTE:
Perform this procedure only if the brake warning lamp is ON, or the customer reports the warning lamp was ON in the past.
Brake Master Cylinder Inspection
1. Cover fenders and painted areas to protect them from possible brake fluid splashing.
2. Locate the brake booster vacuum tube.
3. Carefully pull the vacuum tube from the brake booster (see Figure 2).
4. Remove the rubber grommet from the brake booster (see Figure 2).
IMPORTANT
CAUTION:
If brake fluid is splashed on painted surfaces, immediately wipe off with a clean soft cloth and wash with water.
5. Connect Special Tool J-49749 as shown in Figure 3. Use shop air supply pressure between 90 and 120 psi.
6. Move/position the suction tube inside the brake booster so that any fluid in the lower area of the brake booster is sucked into the collection container.
NOTE:
If there is fluid in the lower area of the booster:
^
Keep the collection container upright.
^
If the collection container fills to within 1/2 inch of the top, empty it and then continue.
^
Continue suction until all of the fluid is removed.
7. After you have removed any / all fluid from the brake booster, disconnect the tool and check the collection container.
OK - No fluid in the container:
^
Reinstall all parts removed.
^
Make sure the brake fluid reservoir is full.
^
Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).
^
Review results of the Multi-Point Inspection with the customer.
NG - Any amount of fluid in the container:
^
Replace the Brake Master Cylinder - Instructions starting below.
^
Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).
^
Review results of the Multi-Point Inspection with the customer.
NOTE:
Once fluid is removed from the booster, the booster does not need to be replaced.
IMPORTANT
Brake Master Cylinder Replacement
1. Write down the radio station presets.
2. If equipped, write down the customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed).
3. Cover fenders and painted areas to protect them from possible brake fluid splashing.
CAUTION:
If brake fluid is splashed on painted surfaces, immediately wipe off with a soft cloth and wash with water.
4. Disconnect the negative battery cable.
5. Disconnect the electrical connector from the Mass Air Flow Sensor.
6. Remove the items shown in Figure 5 (4 cyl) or Figure 6 (6 cyl).
7. Disconnect the brake fluid level sensor connector.
8. Disconnect the harness mount from the side of the fluid reservoir.
9. Drain the fluid from the brake master reservoir as follows:
a. Make sure the parking brake is set.
b. Attach a vinyl tube with catch container to a caliper bleed valve.
d. Open the bleed valve.
e. Slowly pump the brake pedal until the brake fluid reservoir is empty.
CAUTION:
^
If equipped with manual transmission, do not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
^
If brake fluid is splashed on painted surfaces, immediately wipe off with a soft cloth and wash with water.
10. If equipped with manual transmission, remove the fluid supply tube for the clutch master cylinder.
CAUTION:
Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
11. Disconnect the 2 brake lines.
12. Remove the 2 nuts for the brake master cylinder and remove the master cylinder.
NOTE:
Discard old brake master cylinder.
13. Prepare for installation of the new master cylinder:
^
Clean the brake booster in and around the hole for the master cylinder.
^
Make sure the brake master cylinder to booster seal is in place and fully seated as shown.
^
Make sure the primary piston and seal are clean and free of any debris.
CAUTION:
^
Do Not scratch the master cylinder primary piston.
^
Do Not allow the primary piston to contact the brake booster during installation.
14. Install the brake master cylinder and tighten the nuts.
^
Nut Torque:15 Nm (1.5 kg-m, 11 ft-lb)
15. Attach the brake lines.
^
Brake line flare nut torque:18.2 Nm (1.9 kg-m, 13 ft-lb)
16. If equipped with manual transmission, install the fluid supply tube for the clutch master cylinder.
CAUTION:
Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.
17. Re-connect the brake fluid level sensor connector.
18. Re-connect the harness mount to the side of the fluid reservoir.
19. Make sure the rubber grommet and vacuum tube are installed into the brake booster.
20. Re-install the items shown in Figure 5 (4 cyl) or Figure 6 (6 cyl).
21. Re-connect the electrical connector for the Mass Air Flow Sensor.
22. Bleed air from the brake system as follows:
NOTE:
^
Keep brake fluid reservoir filled at least half full while performing the brake bleeding procedure.
^
Use a new fresh sealed bottle of genuine Nissan Super Heavy Duty Brake Fluid (P/N 999MP-A4100P).
a. Attach a vinyl tube with catch container to the right rear brake caliper or wheel cylinder bleed valve.
b. Fully depress brake pedal 4 to 5 times.
c. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
d. Repeat steps b and c until no more air comes out.
e. Tighten bleed valve. Torque to 8.3 Nm (0.85 kg-m, 73 in-lb).
f. Repeat steps a to e for the other wheels in the following order:
Left Front > Left Rear > Right Front
23. If equipped with manual transmission, make sure the clutch is operating correctly by pumping/cycling the clutch pedal 3 or 4 times.
24. Reset the clock and the radio station presets.
25. If equipped; reset customer's settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed.)
26. Initialize auto-up power windows as follows:
a. Turn the ignition ON (keep the transmission in Park and the parking brake applied).
b. Close the door.
C. Operate the power window switch to fully open the window.
d. Pull UP and continue to pull UP on the power window switch to fully close the window.
e. Continue pulling the power window switch UP for 4 seconds after glass stops at fully closed position.
f. Check that auto-up function operates normally.
27. Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).
28. Review results of the Multi-Point Inspection with the customer.
