Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Master Cylinder

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable. Clean the outside of the master cylinder thoroughly, particularly around the cap and fluid lines. Disconnect the fluid lines and cap them to exclude dirt.
  2.  
  3. If equipped with a fluid level sensor, disconnect the wiring harness from the master cylinder.
  4.  
  5. Disconnect the brake fluid tubes, then plug the openings to prevent dirt from entering the system.
  6.  
  7. Remove the mounting bolts at the firewall or the brake booster (if equipped) and remove the master cylinder from the vehicle.
  8.  

To install:
  1. Bench bleed the master cylinder assembly before installation-refer to the service procedure below. Install the master cylinder to the vehicle. Connect all brake lines and fluid level sensor wiring is so equipped. Refill the reservoir with brake fluid and bleed the system. Adjust the brake system if necessary.
  2.  

Ordinary brake fluid will boil and cause brake failure under the high temperatures developed in disc brake systems; use DOT 3 brake fluid in the brake systems. The adjustable pushrod is used to adjust brake pedal free-play. If the pushrod is not adjustable, there will be shims between the cylinder and the mount. These shims, or the adjustable pushrod, are used to adjust brake pedal free play.

MASTER CYLINDER BLEEDING



  1. Place the master cylinder in a vise.
  2.  
  3. Connect two lines to the fluid outlet orifices, and into the reservoir.
  4.  
  5. Fill the reservoir with brake fluid.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Brake booster-1992 240SX



Click image to see an enlarged view

Fig. Fig. 2: Bench bleeding the master cylinder

  1. Using a wooden dowel, depress the pushrod slowly, allowing the pistons to return. Do this several times until the air bubbles are all expelled.
  2.  
  3. Remove the bleeding tubes from the master cylinder, plug the outlets and install the caps.
  4.  

 
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