service INFINITI FX35 2004 Owners Manual
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2004, Model line: FX35, Model: INFINITI FX35 2004Pages: 4449, PDF Size: 99.66 MB
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BODY REPAIR
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Revision: 2004 November2004 FX35/FX45
Replacement OperationsAIS0062A
DESCRIPTION
This section is prepared for technicians who have attained a high level of skill and experience in repairing col-
lision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig-
inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains
additional information, including cautions and warning, that are not including in this manual. Technicians
should refer to both manuals to ensure proper repairs.
Please note that these information are prepared for worldwide usage, and as such, certain procedures might
not apply in some regions or countries.
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BODY REPAIR
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Revision: 2004 November2004 FX35/FX45
lFront pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is
at position A due to the construction of the vehicle. Refer to the
front pillar section.
lDetermine cutting position and record distance from the locating
indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm above inner front pillar cut position.
lPrepare a cutting jig to make outer pillar easier to cut. Also, this
will permit service part to be accurately cut at joint position.
lAn example of cutting operation using a cutting jig is as follows.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig. (At position A)
4. Remove jig and cut remaining portions.
5. Cut inner pillar at position B in same manner.
PIIA0150E
PIIA0151E
PIIA0152E
PIIA0153E
Page 1094 of 4449
BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
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Revision: 2004 November 2004 FX35/FX45
BRAKE SYSTEM
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
PLAY AND CLEARANCE BETWEEN BRAKE
PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED ........................................................ 6
ADJUSTMENT ...................................................... 7
Removal and Installation .......................................... 7
COMPONENT PARTS LOCATION ....................... 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 Piping and
Brake Hose ............................................................. 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Removal and Installation of Rear Brake Piping and
Brake Hose ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 12
BRAKE MASTER CYLINDER .................................. 13
On-board Inspection ............................................... 13
LEAK INSPECTION ............................................ 13Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Components ........................................................... 13
Disassembly and Assembly .................................... 14
DISASSEMBLY ................................................... 14
ASSEMBLY ......................................................... 14
BRAKE BOOSTER ................................................... 15
On-Vehicle Service ................................................. 15
OPERATING CHECK .......................................... 15
AIRTIGHT CHECK .............................................. 15
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 16
INSTALLATION ................................................... 17
VACUUM LINES ....................................................... 18
Removal and Installation ........................................ 18
Inspection ............................................................... 18
VISUAL INSPECTION ......................................... 18
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
... 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 ................................................. 25
On-vehicle Inspection ............................................. 25
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BR-2Revision: 2004 November 2004 FX35/FX45PAD WEAR INSPECTION ................................... 25
Components ........................................................... 25
Removal and Installation of Brake Pad ................... 26
REMOVAL ........................................................... 26
INSTALLATION .................................................... 26
Removal and Installation of Brake Caliper Assembly
... 26
REMOVAL ........................................................... 26
INSTALLATION .................................................... 26
Disassembly and Assembly of Brake Caliper Assembly ................................................................ 27
DISASSEMBLY .................................................... 27
CALIPER INSPECTION ....................................... 27
ASSEMBLY .......................................................... 28
DISC ROTOR INSPECTION ............................... 29
BRAKE BURNISHING PROCEDURE ................. 29
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Brake Pedal ............................................................ 31
Brake Booster ......................................................... 31
Check Valve ............................................................ 31
Front Disc Brake ..................................................... 31
Rear Disc Brake ...................................................... 32
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PRECAUTIONS
BR-3
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Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AFS0028A
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake SystemAFS001MQ
Recommended fluid is brake fluid “DOT 3”.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas.
To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
Use flare nut wrench when removing and installing brake tube.
When installing brake piping, be sure to check torque.
Before working, turn ignition switch OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery
terminal.
Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal
occurs at very low mileage.
Refer to BR-24, "
BRAKE BURNISHING PROCEDURE" .
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.SBR686C
Page 1097 of 4449
BR-4
PREPARATION
Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Commercial Service ToolsAFS001MR
Tool nameDescription
1. Flare nut crowfoot
a:10 mm (0.39 in) / 12 mm (0.47 in)
2. Torque wrenchRemoving and installing each brake
piping
Power toolRemoving front and rear caliper
assembly, tires
S-NT360
PBIC0190E
PBIC0191E
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BRAKE BOOSTER
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Revision: 2004 November 2004 FX35/FX45
BRAKE BOOSTERPFP:47200
On-Vehicle ServiceAFS001N6
OPERATING CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure the clearance between brake pedal
and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
AIRTIGHT CHECK
Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure dis-
tance between brake pedal and floor panel gradually increases.
Depress brake pedal while engine is running, and stop
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for 30 seconds.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
BRA0037D
SBR365AA
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FRONT DISC BRAKE
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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 it a soft
pedal occurs at very low mileage. Refer to BR-24, "
BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake PadAFS001RZ
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with a wire and remove pad and shim from torque member.
INSTALLATION
1. Attach inner shim and shim cover to inner pad, and outer shim to outer pad.
2. Push piston in so that pad is firmly installed 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.
3. Attach pat retainer to torque member.
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.
4. Install lower sliding pin bolt and tighten it to the specified torque.
5. Check brake for drag.
6. Attach tires to the vehicle.
Removal and Installation of Brake Caliper AssemblyAFS001S0
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
3. Remove union bolts and torque member bolts, and remove brake caliper assembly from the vehicle.
4. Remove disc rotor.
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT3”
Do not reuse drained brake fluid.
1. Install disc rotor.
PFIA0273E
Page 1117 of 4449
BR-24
FRONT DISC BRAKE
Revision: 2004 November 2004 FX35/FX45
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 10mm (0.39 in)
inside the disc edge.)
NOTE:
Make sure that wheel bearing axial endplay is with in 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 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.
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.Runout limit
(with it 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
Page 1119 of 4449
BR-26
REAR DISC BRAKE
Revision: 2004 November 2004 FX35/FX45
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
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 it a soft
pedal occurs at very low mileage. Refer to BR-29, "
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.
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.
PFIA0413E