With VDC Models: Assembly

WARNING: This page is about a different car, the 2005 Nissan Quest. However, it is still accessible from the selected car via links, so may be relevant.

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, 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.

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.
CAUTION:
- Pay attention to the orientation of the piston cups. Also, insert pistons squarely to prevent scratching the cylinder inner wall.
- Always replace the inner kit as an assembly.
  
  Fig 1: Identifying Secondary Piston Assembly & Primary Piston Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.
Align the slit in the center of the secondary piston with the axial direction of the piston stopper. Visually check the secondary piston slit from the piston stopper hole and install the piston stop per.

Fig 2: Installing Piston Stopper
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert the plates and the guide into the cylinder body as shown.
CAUTION:
- Be careful not to damage the primary piston rod.
- Pay attention to the orientation of the guide.
  
  Fig 3: Inserting Plate & Guide Into Cylinder Body
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press in the primary piston and install a new snap ring.
CAUTION:
- Make sure snap ring is fully inserted in the snap ring groove.
- Do not reuse snap ring.
Secure master cylinder assembly in a vise as described in disassembly step 1.

Fig 4: Pressing In Primary Piston
Courtesy of NISSAN MOTOR CO., U.S.A.
Using a pin punch [commercial service tool: diameter Approx. 4 mm (0.16 in)], attach the reservoir tank mounting pin so that the attachment side and the opposite side are identical.
CAUTION: Do not reuse reservoir tank grommet and mounting pin.
If necessary, install brake fluid level switch.

Fig 5: Installing Reservoir Tank Mounting Pin
Courtesy of NISSAN MOTOR CO., U.S.A.