Nissan 240SX/Altima 1993-1998 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 1: Disconnect the brake lines (arrows) from the master cylinder



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Fig. Fig. 2: The master cylinder is mounted on two studs protruding from the firewall



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Fig. Fig. 3: Always use a flare nut wrench when tightening or loosening the brake tube fittings



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Fig. Fig. 4: The master cylinder uses a brake fluid level sensor. The connector (arrow) is located at the side of the reservoir



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Fig. Fig. 5: All brake tubes use double flare connections for a leakproof seal



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Fig. Fig. 6: Master cylinder ports are identified as controlling the front (F) or rear (R) brake circuits



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Fig. Fig. 7: The brake fluid reservoir is attached to the master cylinder using rubber grommets (arrows)



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Fig. Fig. 8: The master cylinder pushrod length must be checked with vacuum applied to the brake booster



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Fig. Fig. 9: A vacuum pump comes in handy to siphon brake fluid from the reservoir

  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the brake fluid level sensor electrical harness from the reservoir.
  4.  
  5. Clean the outside of the master cylinder thoroughly, particularly around the cap and fluid lines.
  6.  
  7. Disconnect and cap the brake fluid lines to prevent dirt from entering the system.
  8.  
  9. Remove the master cylinder mounting nuts and lift the master cylinder from the brake booster.
  10.  

To install:

Vehicles with adjustable pushrods will have an adjustable clevis with a locknut at the brake pedal connection under the dashboard.

  1. On vehicles equipped with an adjustable pushrod, adjust the pushrod length.
    1. Apply approximately 17 in. Hg of vacuum to the brake booster using a hand operated vacuum pump.
    2.  
    3. Measure the output rod length from the end of the rod to the front face of the booster, as illustrated.
    4.  
    5. The dimension of the rod should be 0.2023-0.2122 in. (8.253-8.323mm).
    6.  

  2.  
  3. Bench bleed the master cylinder assembly prior to installation.
  4.  
  5. Install the master cylinder and tighten the mounting nuts to 7-9 ft. lbs. (12-13 Nm).
  6.  
  7. Connect the brake lines and tighten to 9-9 ft. lbs. (13-16 Nm).
  8.  
  9. Fill the brake system with fresh, clean fluid.
  10.  
  11. Bleed the brake system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Connect the brake fluid level sensor electrical harness.
  16.  
  17. Check for fluid leaks and verify proper brake system operation.
  18.  

 
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