INFINITI QX4 2005 Factory Service Manual

BL-204
BODY REPAIR
Revision: October 20052005 QX56
WIIA0283E

BODY REPAIR
BL-205
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: October 20052005 QX56
REAR SIDE MEMBER
WIIA0281E

BL-206
BODY REPAIR
Revision: October 20052005 QX56
REAR FLOOR REAR


WIIA0282E

BODY REPAIR
BL-207
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: October 20052005 QX56
CRUSH HORN

Work after 1st crossmember has been removed.
Portions to be welded:
A. Inner side rail crush horn, inner side rail crush horn and outer side rail crush horn.
B. Outer side rail crush horn, outer side rail crush horn and inner side rail crush horn.
LIIA1083E

BL-208
BODY REPAIR
Revision: October 20052005 QX56
Removal Notes

Scribe a straight line on the outer side rail crush horn and inner side rail crush horn along the hole center
as shown in the figure.

Cut off outer side rail crush horn and inner side rail crush horn along scribed line A. Do not cut on the hole.

Cut inner side rail crush horn at 45 mm backward cut position of cut line A. (along line B)
LIIA1084E
LIIA1085E

BODY REPAIR
BL-209
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: October 20052005 QX56

After removing outer panel, dress area on the inner panel surface with a sander or equivalent.
LIIA1086E

BL-210
BODY REPAIR
Revision: October 20052005 QX56
Installation Notes

Scribe a straight line on the inner side rail crush horn along the hole center as shown in the figure. Cut off
inner side rail crush horn along scribed line.

Scribe a straight line on the outer side rail crush horn along the hole center as shown in the figure. Cut off
outer side rail crush horn along scribed line.
LIIA1087E
LIIA1088E

BODY REPAIR
BL-211
C
D
E
F
G
H
J
K
L
MA
B
BL
Revision: October 20052005 QX56

Weld part to be butt-welded and seam-welded corner to corner as shown in the figure.
LIIA1089E

BL-212
BODY REPAIR
Revision: October 20052005 QX56

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BR
A
B
BR
Revision: October 20052005 QX56 PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
INSPECTION ........................................................ 6
ADJUSTMENT ...................................................... 6
Removal and Installation .......................................... 7
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
On-board Inspection ................................................. 9
LEVEL CHECK ..................................................... 9
Drain and Refill ......................................................... 9
Bleeding Brake System .......................................... 10
BRAKE PIPING AND HOSE .....................................11
Hydraulic Circuit ......................................................11
Removal and Installation of Front Brake Hose ........11
REMOVAL ............................................................11
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Hose ....... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-board Inspection ............................................... 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14INSTALLATION ................................................... 15
Disassembly and Assembly .................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 15
BRAKE BOOSTER ................................................... 16
On-Vehicle Service ................................................. 16
OPERATING CHECK .......................................... 16
AIRTIGHT CHECK .............................................. 16
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
VACUUM LINES ....................................................... 19
Removal and Installation ........................................ 19
Inspection ............................................................... 19
VISUAL INSPECTION ......................................... 19
CHECK VALVE INSPECTION ............................. 19
FRONT DISC BRAKE ............................................... 20
On-vehicle Inspection ............................................. 20
PAD WEAR INSPECTION ................................... 20
Components ........................................................... 20
Removal and Installation of Brake Pad .................. 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
Removal and Installation of Brake Caliper Assembly
and Disc Rotor ........................................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 22
DISASSEMBLY ................................................... 22
CALIPER INSPECTION ...................................... 23
ASSEMBLY ......................................................... 23
DISC ROTOR INSPECTION ............................... 24
BRAKE BURNISHING PROCEDURE ................. 24
REAR DISC BRAKE ................................................. 26
On-vehicle Inspection ............................................. 26
PAD WEAR INSPECTION ................................... 26
Components ........................................................... 26
Removal and Installation of Brake Pad .................. 27
REMOVAL ........................................................... 27