1998 NISSAN PICK-UP Repair Manual

Disassembly
1. Bend claws of stopper cap outward.
2. Remove piston assemblies.
lIf it is difficult to remove secondary piston assembly,
gradually apply compressed air through fluid outlet.
3. Draw out reservoir tank.
Inspection
Check master cylinder inner wall for pin holes or scratches.
Replace if damaged.
Assembly
1. Insert secondary piston assembly. Then insert primary piston
assembly.
lPay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cyl-
inder bore.
SBR938A
SBR939A
SBR012AB
SBR089CA
MASTER CYLINDER
BR-13

2. Install stopper cap.
lBefore installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
Installation
CAUTION:
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mount-
ing nuts lightly.
2. Tighten mounting nuts.
: 12 - 15 N´m (1.2 - 1.5 kg-m,9-11ft-lb)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction 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.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
8. Bleed air from brake system. Refer to ``Bleeding Brake
System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR940A
ABR190
MASTER CYLINDER
Assembly (Cont'd)
BR-14

On-vehicle Service
OPERATING CHECK
lDepress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
lDepress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
lStart engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
lDepress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for30 seconds.
Removal
CAUTION:
lBe careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
lBe careful not to deform or bend brake pipes during
removal of booster.
Inspection
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of þ66.7 kPa (þ667 mbar, þ500 mmHg,
þ19.69 inHg) to brake booster with a hand vacuum pump.
2. Check output rod length.
Specified length:
10.275 - 10.525 mm (0.4045 - 0.4144 in)
SBR002A
SBR365AA
ABR373
SBR281A
BRAKE BOOSTER
BR-15

Installation
CAUTION:
lBe careful not to deform or bend brake pipes during
installation of booster.
lReplace clevis pin if damaged.
lRefill with new brake fluid DOT 3 or DOT 4*1.
lNever reuse drained brake fluid.
lTake care not to damage brake booster mounting bolt
thread when installing. Due to the narrow angle of
installation, the threads can be damaged by the dash
panel.
A: S230, M215T
LHD 165 mm (6.50 in)
RHD 185 mm (7.28 in)
M195T
LHD 160 mm (6.30 in)
RHD 180 mm (7.09 in)
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
: 13 - 16 N´m (1.3 - 1.6 kg-m,9-12ft-lb)
5. Install master cylinder. Refer to ``Installation'', ``MASTER
CYLINDER'', BR-14.
6. Adjust brake pedal height and free play. Refer to BR-11.
7. Secure lock nut for clevis.
: 16 - 22 N´m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
8. Bleed air. Refer to ``Bleeding Brake System'', BR-4.
*1: Refer to MA section (``Fluids and Lubricants'', ``RECOM-
MENDED FLUIDS AND LUBRICANTS'').
SBR116BE
BRAKE BOOSTER
BR-16

Removal and Installation
CAUTION:
When installing vacuum hoses, pay attention to the follow-
ing points.
lDo not apply any oil or lubricants to vacuum hose and
check valve.
lInsert vacuum tube into vacuum hose as shown.
lInstall check valve, paying attention to its direction.
Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for
airtightness, improper attachment chafing and deterioration.
CHECK VALVE
Check vacuum with a vacuum pump.
Connect to booster
sideVacuum should exist.
Connect to engine
sideVacuum should not exist.
SBR225B
SBR498AB
.LHD KA24 engine model
SBR826BB
.TD25 engine model
SBR943AC
.LHD KA24 engine model.
VACUUM HOSE
BR-17

VACUUM WARNING SWITCH*
Test continuity through vacuum warning switch with an ohmme-
ter and vacuum pump.
VacuumLess than 26.7 kPa
(267 mbar, 200 mmHg, 7.87 inHg)0W
33.3 kPa
(333 mbar, 250 mmHg, 9.84 inHg) or more
W
*Diesel engine models
SBR844BC
.
.TD25 engine model
SBR007A
VACUUM HOSE
Inspection (Cont'd)
BR-18

Removal and Installation
Inspection
CHECK VALVE
1. Check valve operation. Check that valve operates smoothly
when slightly pushed. Replace if necessary.
2. Check for air leakage with 98 to 490 kPa (1.0 to 4.9 bar, 1 to
5 kg/cm
2, 14 to 71 psi) of air pressure.
Replace if necessary.
SBR974D
SBR194
SBR195
VACUUM PUMP
BR-19

VACUUM
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
86.6 kPa (866 mbar, 650 mmHg, 25.59 inHg) or
more
SBR975D
VACUUM PUMP
Inspection (Cont'd)
BR-20