brake INFINITI FX35 2005 Service Manual

INTELLIGENT KEY SYSTEM BL-121
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ACTIVE TEST
ACC SW [ON/OFF] Displays status (Ignition switch ACC position: ON/Ignition switch OFF position:
OFF) as judged from ignition switch signal.
DOOR STAT SW [ON/OFF] Displays status from door unlock sensor ON/OFF condition.
STOP LAMP SW [ON/OFF] Displays status (Brake pedal depress: ON/brake pedal not depress: OFF) as
judged from stop lamp switch signal.
P RANGE SW [ON/OFF] Displays status from park/neutral position switch ON/OFF condition.
BD OPEN SW [ON/OFF] Displays status (Back door open: ON/Back door closed: OFF) as judged from back
door opener switch signal.
CAN COMM [ON/OFF] Display CAN communication system.
CAN CIRC 1 [ON/OFF] Display CAN communication system.
CAN CIRC 2 [ON/OFF] Display CAN communication system.
CAN CIRC 3 [ON/OFF] Display CAN communication system.
CAN CIRC 4 [ON/OFF] Display CAN communication system. Monitor item [OPERATION] Description
Monitor item Description
DOOR LOCK/UNLOCK This test is able to check all door lock actuators lock/unlock operation. These
actuators lock when “ON” on CONSULT-II screen is touched.
OUTSIDE BUZZER This test is able to check Intelligent Key warning buzzer operation. The buzzer will
be activated on when “ON” on CONSULT-II screen is touched.
INSIDE BUZZER This test is able to check buzzer (bultin combination meter) operation. The buzzer
will be activated on when “ON” on CONSULT-II screen is touched.
INDICATOR This test is able to check warning lamp operation. The lamp will be turned on
when “ON” on CONSULT-II screen is touched.

BL-146
INTELLIGENT KEY SYSTEM
Revision: 2005 July 2005 FX
4. CHECK STEERING LOCK UNIT COMMUNICATION CIRCUIT
1. Disconnect Intelligent Key unit and steering lock unit connectors.
2. Check continuity between Intelligent Key unit connector M34 terminals 1, 31, 32 and steering lock unit connector M26 terminals 2, 3, 4.
3. Check continuity between steering lock unit connector M26 ter- minals 2, 3, 4 and ground.
OK or NG
OK >> Replace steering lock unit.

After replacing steering lock unit, perform registration procedure. Refer to “CONSULT-II Opera-
tion Manual NATS-IVIS/NVIS”.
NG >> Repair or replace harness between steering lock unit and Intelligent Key unit.
Check Stop Lamp SwitchAIS004NM
1. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Disconnect stop lamp switch connector.
2. Check voltage between stop lamp switch connector E210 termi- nal 1 (GY) and ground.
OK or NG
OK >> GO TO 2.
NG >> Repair or replace harness between stop lamp switch and fuse.
2. CHECK STOP LAMP SWITCH OPERATION
Check continuity between stop lamp switch connector E210 terminal
1 and 2.
OK or NG
OK >> GO TO 3.
NG >> Replace stop lamp switch. 1 (R/W) - 2 (R/W) : Continuity should exist.
31 (Y/B) - 4 (Y/B) : Continuity should exist.
32 (R/B) - 3 (R/B) : Continuity should exist.
2 (R/W) - Ground : Continuity should not exist. 3 (R/B) - Ground : Continuity should not exist.4 (Y/B) - Ground : Continuity should not exist.
PIIA6799E
1 (GY) - Ground : Battery voltage
PIIA6811E
1 - 2
Brake pedal depressed : Continuity should exist.
Brake pedal not
depressed : Continuity should not exist.
PIIA6800E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
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Revision: 2005 July 2005 FX
BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ............................................................. ..... 3
Precautions for Procedures without Cowl Top Cover ..... 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 .........................................
... 13
Removal 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 .............. ... 25
REAR DISC BRAKE .............................................. ... 26

BR-2Revision: 2005 July 2005 FX
On-Vehicle Inspection ..........................................
... 26
PAD WEAR INSPECTION ................................ ... 26
Components ........................................................ ... 26
Removal and Installation of Brake Pad ................ ... 27
REMOVAL ........................................................ ... 27
INSTALLATION ................................................. ... 27
Removal and Installation of Brake Caliper Assembly ... 27
REMOVAL ........................................................ ... 27
INSTALLATION ................................................. ... 28
Disassembly and Assembly of Brake Caliper Assembly .............................................................
... 28
DISASSEMBLY ................................................. ... 28
CALIPER INSPECTION .................................... ... 29
ASSEMBLY ....................................................... ... 29
DISC ROTOR INSPECTION ............................ ... 30
BRAKE BURNISHING PROCEDURE .............. ... 31
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 32
General Specifications ......................................... ... 32
Brake Pedal ......................................................... ... 32
Brake Booster ...................................................... ... 32
Check Valve ......................................................... ... 32
Front Disc Brake .................................................. ... 32
Rear Disc Brake ................................................... ... 32

PRECAUTIONS BR-3
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Revision: 2005 July 2005 FX
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 Procedures without Cowl Top CoverAFS0038B
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
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-25, "
BRAKE BURNISHING PROCEDURE" .
WARNING:

Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
PIIB3706J
SBR686C

BR-4
PREPARATION
Revision: 2005 July 2005 FX
PREPARATIONPFP:00002
Commercial Service ToolsAFS001MR
Tool nameDescription
1. Flare nut crowfoot a:10 mm (0.39 in) / 12 mm (0.47 in)
2. Torque wrench Removing and installing each brake
piping
Power tool Removing front and rear caliper
assembly, tires
S-NT360
PBIC0190E
PBIC0191E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING BR-5
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Revision: 2005 July 2005 FX
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartAFS001MS
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: Applicable
Reference page
BR-20
,
BR-26
BR-20
, BR-26
BR-20
, BR-26—
—
BR-24, BR-30—
—
—
BR-24, BR-31

—
NVH in PR section
NHV in RFD section
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in RAX section
NVH in PS section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
Symptom BRAKE Noise
××× ×× ×××
××
Shake ×××××
××
Shimmy, Judder ××××××× ××× ×

BR-6
BRAKE PEDAL
Revision: 2005 July 2005 FX
BRAKE PEDALPFP:46501
Inspection and AdjustmentAFS001MT
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED
1. Check brake pedal height from dash lower panel.
2. Adjust height referring to the following specifications.
SFIA1450E
H Brake pedal free height (from dash lower panel
top surface) 161.5
− 171.5 mm (6.36 − 6.75 in)
D Brake pedal depressed height [under a force of
490 N (50 kg, 110 lb) with engine running] More than 80 mm (3.15 in)
C Clearance between bracket and the threaded end
of stop lamp switch or ASCD cancel switch (or
brake switch) 0.74
− 1.96 mm (0.0291 −0.0772 in)
A Pedal play 3 − 11 mm (0.12 − 0.43 in)

BRAKE PEDAL BR-7
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Revision: 2005 July 2005 FX
ADJUSTMENT
1. Loosen stop lamp switch and ASCD cancel switch (or brake
switch) by turning it counterclockwise by 45 °.
2. Loosen lock nut (A) on input rod, then rotate input rod to set pedal to the specified height, and tighten lock nut (A).
CAUTION:
Make sure the threaded end of input rod stays inside clevis.
3. With pedal pulled and held by hand, press stop lamp switch and ASCD cancel switch (or brake switch) until its threaded end con-
tacts stopper rubber.
4. With the threaded end of stop lamp switch and ASCD cancel switch (or brake switch) contacting stopper rubber, rotate switch
clockwise by 45 ° to secure.
CAUTION:
Make sure that the clearance (C) between stopper rubber
and threaded end of stop lamp switch and ASCD cancel
switch (or brake switch) is within the standard.
5. Check pedal play. CAUTION:
Make sure that stop lamps go off when pedal is released.
6. Start engine to check brake pedal depressed height.
Removal and InstallationAFS001MU
COMPONENT PARTS LOCATION
Lock nut (A) :
Refer to BR-16, "
Removal and Installation"
SFIA0160E
SFIA1940E

BR-8
BRAKE PEDAL
Revision: 2005 July 2005 FX
REMOVAL
1. Remove front kicking plate (driver side). EI-38, "KICKING PLATE" .
2. Remove dash side finisher (driver side). EI-37, "
DASH SIDE FINISHER" .
3. Remove instrument lower panel (driver side). IP-18, "
INSTRUMENT PASSENGER LOWER PANEL" .
4. Remove steering column assembly. Refer to PS-12, "
Removal and Installation" .
5. Remove stop lamp switch and ASCD cancel switch (or brake switch) from pedal assembly.
6. Remove snap pin and clevis pin from brake booster clevis.
7. Remove mounting nuts and bolts from bracket, and remove pedal assembly from the vehicle.
INSPECTION AFTER REMOVAL

Make sure the rivets in the upper part of brake pedal are not
deformed.

Make sure sub bracket and slide plate are at least 4 mm (0.16
in) apart.

Check brake pedal for bend, damage, and cracks on the welded
parts. Replace the applicable part if a malfunction is detected.

Check clevis pin and resin stopper for damage and deformation.
If a malfunction is detected, replace clevis pin.
INSTALLATION
Note the following, and install in the reverse order of removal.

After installing brake pedal assembly to the vehicle, adjust brake pedal height.
1. Clevis pin 2. Snap pin 3. Brake pedal assembly
4. Stopper rubber 5. Pedal pad 6. ASCD cancel switch (Models with ASCD)
Brake switch (Models with ACC)
7. Stop lamp switch 8. Clip
SFIA0159E
PFIA0223E
SBR997