INFINITI FX35 2005 Service Manual

BR-22
FRONT DISC BRAKE
Revision: 2005 July 2005 FX

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque.
CAUTION:
When attaching caliper assembly to the vehicle, wipe any
oil off knuckle spindle, washers and caliper assembly
attachment surfaces.
3. Install brake hose to brake caliper assembly, and tighten union bolt to the specified torque.
CAUTION:

Do not reuse copper washers for union bolt.

Attach brake hose to caliper assembly together with
union bolt and washers.
4. Refill new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
5. Attach tires to the vehicle.
Disassembly and Assembly of Brake Caliper AssemblyAFS001S1
DISASSEMBLY
1. Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque member.
2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
SFIA1205E
SFIA1204E
MAA0272D

FRONT DISC BRAKE BR-23
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Revision: 2005 July 2005 FX
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION:
Be careful not to damage cylinder inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.

Check inside surface of cylinder for score, rust, wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.

Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
To r q u e M e m b e r
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
dition are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials are
stuck to sliding surface.
Sliding Pins and Sliding Pin Boots
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
ASSEMBLY
CAUTION:
When assembling, use only rubber lubricant specified below.
1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body.
SFIA0999E
SFIA2278E

BR-24
FRONT DISC BRAKE
Revision: 2005 July 2005 FX
2. Apply brake fluid to piston, rubber grease to piston boot, then
install piston boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.
5. Attach inner shim and inner shim cover to inner pad, and attach the outer shim to the outer pad.
6. Install cylinder body. Tighten sliding pin bolt to the specified torque.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheel hub. (2 or more positions)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside the disc edge.]
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-4, "
On-Vehicle
Inspection and Service" .
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one hole.
4. If runout is still out of specification, turn rotor with on-car brake lathe. (“MAD DL-8700”, “AMMCO 700 and 705” or equivalent.)
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the standard, replace disc rotor.
SFIA2279E
Runout limit
(with the disc rotor attached to
the vehicle) : 0.04 mm (0.0016 in)
Runout limit
(just the disc rotor) : 0.02 mm (0.0008 in)
BRA0013D
Standard thickness : 28.0 mm (1.102 in)
Repair limit thickness : 26.0 mm (1.024 in)
Maximum uneven wear
(measured at 8 positions) : 0.015 mm (0.0006 in)
SBR020B

FRONT DISC BRAKE BR-25
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Revision: 2005 July 2005 FX
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

BR-26
REAR DISC BRAKE
Revision: 2005 July 2005 FX
REAR DISC BRAKEPFP:44000
On-Vehicle InspectionAFS001NA
PAD WEAR INSPECTION

Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.
ComponentsAFS001NB
Standard thickness : 8.5 mm (0.335 in)
Repair limit thickness : 2.0 mm (0.079 in)
BRA0010D
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Sliding pin boot
13. Bushing 14. Torque member bolt 15. Torque member
16. Inner shim cover 17. Inner shim 18. Inner pad
19. Pad retainer (Upper) 20. Pad retainer (Lower) 21. Outer pad
22. Outer shim 23. Outer shim cover
Refer to GI-10, "
Components" and the followings for the symbols in the figure.
PFIA0688E

REAR DISC BRAKE BR-27
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Revision: 2005 July 2005 FX
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of airborne
particles or other materials.
CAUTION:

While removing cylinder body, never depress brake pedal because piston will pop out.

It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.

Do not damage piston boot.

If any shim is subject to serious corrosion, replace it with a new one.

Always replace shims and shim covers as a set when replacing brake pads.

Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft
pedal occurs at very low mileage. Refer to BR-31, "
BRAKE BURNISHING PROCEDURE"
Removal and Installation of Brake PadAFS001NC
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove sliding pin bolt (one on top).
3. Suspend cylinder body with a wire, and remove pads, pad retainers, shim from torque member.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the backside of pad and to both sides of shim, and attach inner shim and shim cover to inner pad, and attach the outer shim and outer shim
cover to outer pad.
2. Install pad retainer and mount pad to torque member.
3. Push piston in so that pad is firmly attached and mount cylinder body to torque member. NOTE:
Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
4. Install sliding pin bolt (one on top) and tighten to the specified torque.
5. Check brake for drag.
6. Install tires to the vehicle.
Removal and Installation of Brake Caliper AssemblyAFS001ND
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
3. Remove union bolt and torque member bolts, and remove brake caliper assembly from the vehicle.
4. Remove disc rotor.
1: Rubber grease
2: PBC (Poly Butyl Cuprysil) grease or silicone-based grease
3: Polyglycol ether based lubricant
: Brake fluid
PFIA0413E

BR-28
REAR DISC BRAKE
Revision: 2005 July 2005 FX
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque. CAUTION:
Before installing caliper assembly to the vehicle, wipe off oil and grease on washer seats on axle
assembly and mounting surface of caliper assembly.
3. Install brake hose to caliper assembly and tighten union bolt to the specified torque.
CAUTION:

Do not reuse copper washer for union bolt.

Securely attach brake hose to protrusion on caliper assembly.
4. Refill new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper AssemblyAFS001NE
DISASSEMBLY
1. Remove sliding pin bolt, and then remove pad, shim, shim cover, and pad retainer from torque member and cylinder.
2. Remove sliding pin boot from torque member.
3. As shown in the figure, using a flat-bladed screwdriver, remove retaining ring from cylinder body.
4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
5. Using a flat-bladed screwdriver, remove piston seals from cylin- der body.
CAUTION:
Be careful not to damage cylinder inner wall.
SBR028A
BRD0041D
SFIA0999E

REAR DISC BRAKE BR-29
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Revision: 2005 July 2005 FX
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.

Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
To r q u e M e m b e r
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:

Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials
are stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above condition are observed.
Sliding Pin Bolts and Sliding Pin Boots
Make sure there is no wear, damage, or cracks in sliding pin bolts and sliding pin boots, and if there are,
replace them.
ASSEMBLY
CAUTION:
When assembling, use only rubber lubricant specified below.
1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body.
2. Apply brake fluid to piston rubber grease to piston boot, then install piston boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove. CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder inner wall from being rubbed.
SFIA2278E
SFIA2279E

BR-30
REAR DISC BRAKE
Revision: 2005 July 2005 FX
4. Fix piston boot with retaining ring.
CAUTION:

Make sure boot is firmly in cylinder body groove.

Do not reuse retaining ring.
5. Install sliding pin bolt and sliding pin boots to torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicon-based grease to the backside of pad and to both sides of shim, and attach inner shim and shim cover to inner pad, and the outer shim and outer shim cover to
outer pad.
7. Assembling shims and shim covers to pad. CAUTION:
When attaching pad retainer, attach it firmly so that it does
not float up higher than torque member, as shown in the fig-
ure.
8. Attach pad retainer and pad to torque member.
9. Install cylinder body. Tighten sliding pin bolts to the specified torque.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheel hub. (2 or more positions)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in) inside disk edge.]
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cation before measuring runout. Refer to RAX-5, "
On-Vehicle
Inspection and Service" .
3. If runout is outside the limit, find the minimum runout point by shifting mounting positions of disc rotor and wheel hub by one
hole.
4. If runout still out of specification, turn rotor with on-car brake lathe (“MAD, DL-8700”, “AMMCO 700 and 705” or equivalent).
SFIA2280E
PFIA0273E
Runout limit (with it
attached to the vehicle) : 0.05 mm (0.0020 in)
BRA0013D

REAR DISC BRAKE BR-31
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Revision: 2005 July 2005 FX
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the standard, replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal /foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal /foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear
(measured at 8 positions) : 0.015 mm (0.0006 in)
SBR020B