Assembly (For AWD Model)

WARNING: This page is about a different car, the 2005 Infiniti G35. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes.
Make sure that there is no foreign material such as dirt and dust on the inner wall of cylinder, piston, and piston cup. Be careful not to damage parts with a service tool when assembling.
Do not drop parts. Do not use any dropped parts.

Apply brake fluid to the inner wall of cylinder body, primary piston assembly and secondary piston assembly.
Insert secondary piston and primary piston assembly into cylinder body in this order.
CAUTION:
- Do not reuse primary and secondary piston assemblies.
- Always replace inner kit as a set.
- Pay attention to the orientation of piston cup, and insert straight to prevent cup from being caught by the inner wall of cylinder.
  
  Fig 1: Identifying Secondary Piston And Primary Piston (For AWD Model)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Set the slit of secondary piston towards the piston stopper mounting hole of cylinder body. And then install the piston stopper through the slit of secondary piston.

Fig 2: Installing Piston Stopper Through Slit Of Secondary Piston (For AWD Model)
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert plate and guide assembly into cylinder body.
CAUTION:
- Be careful not to damage rod of primary piston.
- Pay attention to the orientation of guide assembly.
- Do not drop O-ring.
- Be careful the guide and/or plate are not inserted at an angle to cylinder inner wall.
  
  Fig 3: Inserting Plate And Guide Assembly Into Cylinder Body (For AWD Model)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Be careful not to damage rod of primary piston with the cloth. Then insert snap ring to cylinder body with pushing primary piston.
CAUTION:
- Make sure that snap ring is securely engaged in cylinder body inner diameter groove.
- Do not reuse snap ring.
  
  Fig 4: Inserting Snap Ring To Cylinder Body With Pushing Primary Piston (For AWD Model)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Apply brake fluid to a grommet, and press it into master cylinder to install.
CAUTION: Do not reuse grommet
Install reservoir tank to master cylinder.
CAUTION: Pay attention to the orientation of reservoir tank

Fig 5: Installing Reservoir Tank To Master Cylinder (For AWD Model)
Courtesy of NISSAN MOTOR CO., U.S.A.
Secure flange of cylinder body as shown in Fig 6.
CAUTION:
- Using copper plate or cloth to cover flange for securing in the vise.
- When securing master cylinder assembly in a vise, be sure not to over tighten.
- Be sure to secure the flange part with the brake tube installation side down.
  
  Fig 6: Securing Flange Of Cylinder Body (For AWD Model)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Using a pin punch [commercial service tool: diameter approx. 4 mm (0.16 in)], insert the reservoir tank mounting pin into the pin hole so that the insertion side and the opposite side are identical.
CAUTION:
- Pay attention to the orientation of piston cup, and insert straight to prevent cup from being caught by the inner wall of cylinder.
  
  Fig 7: Inserting Reservoir Tank Mounting Pin Into Pin Hole Using Pin Punch (For AWD Models)
  Courtesy of NISSAN MOTOR CO., U.S.A.