Campaign PC125 - Brake Master Cylinder Replacement

Disclaimer2010 Nissan-Datsun Altima L4-2.5L (QR25DE) Technical Service Bulletin # 12-011C Date: 130307

Campaign PC125 - Brake Master Cylinder Replacement

Reference: NTB12-011C

Date: MARCH 7, 2013

VOLUNTARY SERVICE CAMPAIGN

2007-2012 ALTIMA SEDAN & COUPE BRAKE MASTER CYLINDER

This bulletin has been amended. "This Voluntary Service Campaign DOES NOT APPLY to Altima Hybrid (L32H) vehicles" was added to the

Applied Vehicles section. Please discard previous versions.

CAMPAIGN ID #: PC125

APPLIED VEHICLES: 2007 - 2012 Altima Sedan & Coupe (L32 & CL32)

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>> This Voluntary Service Campaign DOES NOT APPLY to Altima Hybrid (L32H) vehicles<<

Refer to the flow chart (Repair Overview) for campaign eligibility.

INTRODUCTION

Nissan is conducting a Voluntary Service Campaign on Model Year 2007-2012 Nissan Altima (L32) Sedan and Coupe vehicles to inspect the brake

system in vehicles with an illuminated brake warning lamp. Nissan dealers will inspect the brake system and confirm that no brake fluid leak is

present. If no leak is present, the reservoir will be topped off. If a leak in the brake master cylinder is identified, the brake master cylinder will be

replaced.

The affected vehicles are equipped with a brake warning lamp that will illuminate to alert the driver when fluid in the brake fluid reservoir is low.

Fluid in the reservoir may become low due to normal brake pad wear and not because of any brake system malfunction. While in most instances an

illuminated brake warning lamp is due to normal brake pad wear, a small percentage of vehicles affected by this campaign may have a slow brake

fluid leak at the brake master cylinder.

IDENTIFICATION NUMBER

Nissan has assigned identification number PC125 to this campaign. This number must appear on all communications and documentation of any

nature dealing with this campaign.

DEALER RESPONSIBILITY

This action is only required if the brake warning lamp is currently illuminated, or the customer states it was recently illuminated while driving. In

addition, this campaign is intended to promote customer satisfaction. This inspection may also be performed based on customer request, regardless

of the warning lamp illumination.

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Repair Overview

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REQUIRED SPECIAL TOOL J-49749

PARTS INFORMATION

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CLAIMS INFORMATION

Disclaimer

Service Procedure

NOTE:

Perform this procedure only if the brake warning lamp is ON, or the customer reports the warning lamp was ON in the past.

Brake Master Cylinder Inspection

1. Cover fenders and painted areas to protect them from possible brake fluid splashing.

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2. Locate the brake booster vacuum tube.

3. Carefully pull the vacuum tube from the brake booster (see Figure 2).

4. Remove the rubber grommet from the brake booster (see Figure 2).

IMPORTANT

CAUTION:

If brake fluid is splashed on painted surfaces, immediately wipe off with a clean soft cloth and wash with water.

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5. Connect Special Tool J-49749 as shown in Figure 3.

^ Use shop air supply pressure between 90 and 120 psi.

6. Move/position the suction tube inside the brake booster so that any fluid in the lower area of the brake booster is sucked into the collection

container.

NOTE:

If there is fluid in the lower area of the booster:

^ Keep the collection container upright.

^ If the collection container fills to within 1/2 inch of the top, empty it and then continue.

^ Continue suction until all of the fluid is removed.

7. After you have removed any / all fluid from the brake booster, disconnect the tool and check the collection container.

OK - No fluid in the container:

^ Reinstall all parts removed.

^ Make sure the brake fluid reservoir is full.

^ Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).

^ Review results of the Multi-Point Inspection with the customer.

NG - Any amount of fluid in the container:

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^ Replace the Brake Master Cylinder - Instructions below.

^ Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).

^ Review results of the Multi-Point Inspection with the customer.

NOTE:

Once fluid is removed from the booster, the booster does not need to be replaced.

IMPORTANT

Brake Master Cylinder Replacement

1. Write down the radio station presets.

2. If equipped, write down the customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed).

3. Cover fenders and painted areas to protect them from possible brake fluid splashing.

CAUTION:

If brake fluid is splashed on painted surfaces, immediately wipe off with a soft cloth and wash with water.

4. Disconnect the negative battery cable.

5. Disconnect the electrical connector from the Mass Air Flow Sensor.

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6. Remove the items shown in Figure 5 (4 cyl) or Figure 6 (6 cyl).

7. Disconnect the brake fluid level sensor connector.

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8. Disconnect the harness mount from the side of the fluid reservoir.

9. Drain the fluid from the brake master reservoir as follows:

a Make sure the parking brake is set.

b. Attach a vinyl tube with catch container to a caliper bleed valve.

d. Open the bleed valve.

e. Slowly pump the brake pedal until the brake fluid reservoir is empty.

CAUTION:

^ If equipped with manual transmission, do not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch

system.

^ If brake fluid is splashed on painted surfaces, immediately wipe off with a soft cloth and wash with water.

10. If equipped with manual transmission, remove the fluid supply tube for the clutch master cylinder.

CAUTION:

Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.

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11. Disconnect the 2 brake lines.

12. Remove the 2 attachment nuts for the brake master cylinder and then remove the brake master cylinder.

NOTE:

Do not reuse the old brake master cylinder.

13. Prepare for installation of the new master cylinder:

^ Clean the brake booster in and around the hole for the master cylinder.

^ Make sure the brake master cylinder to booster seal is in place and fully seated as shown.

^ Make sure the primary piston and seal are clean and free of any debris.

CAUTION:

^ Do Not scratch the master cylinder primary piston.

^ Do Not allow the primary piston to contact the brake booster during installation.

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14. Install the brake master cylinder and tighten the nuts.

^ Nut Torque:

15 N-m (1.5 kg-m, 11 ft-lb)

15. Attach the brake lines.

^ Brake line flare nut torque:

18.2 N-m (1.9 kg-m, 13 ft-lb)

16. If equipped with manual transmission, install the fluid supply tube for the clutch master cylinder.

CAUTION:

Do Not push the clutch pedal when the reservoir is empty or you will need to bleed the clutch system.

17. Re-connect the brake fluid level sensor connector.

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18. Re-connect the harness mount to the side of the fluid reservoir.

19. Make sure the rubber grommet and vacuum tube are installed into the brake booster.

20. Re-install the items shown in Figure 5 (4 cyl) or Figure 6 (6 cyl).

21. Re-connect the electrical connector for the Mass Air Flow Sensor.

22. Bleed air from the brake system as follows:

NOTE:

^ Keep brake fluid reservoir filled at least half full while performing the brake bleeding procedure.

^ Use a new fresh sealed bottle of genuine Nissan Super Heavy Duty Brake Fluid (P/N 999MP-A4100P).

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a. Attach a vinyl tube with catch container to the right rear brake caliper or wheel cylinder bleed valve.

b. Fully depress brake pedal 4 to 5 times.

c. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.

d. Repeat steps b and c until no more air comes out.

e. Tighten bleed valve. Torque to 8.3 N-m (0.85 kg-m, 73 in-lb).

f. Repeat steps a to e for the other wheels in the following order:

Left Front > Left Rear > Right Front

23. If equipped with manual transmission, make sure the clutch is operating correctly by pumping/cycling the clutch pedal 3 or 4 times.

24. Reset the clock and the radio station presets.

25. If equipped; reset customers settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed.)

26. Initialize auto-up power windows as follows:

a. Turn the ignition ON (keep the transmission in Park and the parking brake applied).

b. Close the door.

c. Operate the power window switch to fully open the window.

d. Pull UP and continue to pull UP on the power window switch to fully close the window.

e. Continue pulling the power window switch UP for 4 seconds after glass stops at fully closed position.

f. Check that auto-up function operates normally.

27. Check and fill (top-off) under hood fluids (e.g. washer fluid, coolant, brake fluid).

28. Review results of the Multi-Point Inspection with the customer.

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