leak INFINITI FX35 2005 Owner's Guide

ATC-152
REFRIGERANT LINES
Revision: 2005 July 2005 FX
5. Disconnect one-touch joint between high-pressure pipe 1 and 2.
a. Set a disconnector (SST: 9253089908) on A/C piping.
b. Slide a disconnector toward vehicle rear until it clicks.
c. Slide A/C piping toward vehicle rear and disconnect it. CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
6. Remove high-pressure pipe 1.
7. Disconnect one-touch joint between high-pressure pipe 2 and 3.
a. Set a disconnector (SST: 9253089908) on A/C piping.
b. Slide a disconnector toward vehicle front until it clicks.
c. Slide A/C piping toward vehicle front and disconnect it.
8. Remove high-pressure pipe 2. CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace O-rings of high-pressure pipe with new ones, and then apply compressor oil to it when
installing it.

Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.

Insert one-touch joint connection point securely until it clicks.

After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.

When recharging refrigerant, check for leaks.
Removal and Installation of Low-Pressure Pipe 2 and High-Pressure Pipe 3AJS001BI
REMOVAL
1. Set the temperature (passenger side) at 18 °C (60 °F), and then disconnect the battery cable from the neg-
ative terminal.
2. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
3. Remove cowl top cover. Refer to EI-23, "
COWL TOP" .
4. Remove mounting bolts from low-pressure pipe 1 bracket and low-pressure flexible hose bracket.
RJIA2072E
RJIA2073E
RJIA2068E

ATC-154
REFRIGERANT LINES
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When recharging refrigerant, check for leaks.
Removal and Installation of Liquid TankAJS0015Y
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove front grille. Refer to EI-22, "
FRONT GRILLE" .
3. Clean liquid tank and its surrounding area, and remove dirt and rust from liquid tank. CAUTION:
Be sure to clean carefully.
4. Remove mounting bolts from liquid tank and power steering oil cooler.
5. Lift liquid tank bracket upward. Remove bracket from protruding part of condenser.
6. Slide liquid tank upward, and then remove liquid tank.
INSTALLATION
Install liquid tank, and then install liquid tank bracket on condenser.
CAUTION:

Make sure liquid tank bracket is securely installed at protru-
sion of condenser. (Make sure liquid tank bracket does not
move to a position below center of liquid tank.)

Replace O-rings of A/C piping with new ones, and then
apply compressor oil to it when installing it.

When recharging refrigerant, check for leaks. Low-pressure pipe 1 bracket and low-pressure flexible hose bracket mounting bolts
Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb)
RJIA2074E
RJIA0672E
RJIA0673E

ATC-156
REFRIGERANT LINES
Revision: 2005 July 2005 FX

After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.

When recharging refrigerant, check for leaks.
Removal and Installation of Refrigerant Pressure SensorAJS00160
REMOVAL
1. Remove condenser. Refer to ATC-155, "Removal and Installation of Condenser" .
2. Remove refrigerant pressure sensor from condenser. CAUTION:
When working, be careful not to damage the condenser.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Apply compressor oil to O-ring of refrigerant pressure sensor when installing it.
Removal and Installation of EvaporatorAJS001BJ
REMOVAL
1. Remove low-pressure pipe 2 and high-pressure pipe 3. Refer to ATC-152, "Removal and Installation of
Low-Pressure Pipe 2 and High-Pressure Pipe 3" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
2. Slide evaporator, and then remove it from heater & cooling unit.
3. Remove intake sensor from evaporator, and then remove evap- orator.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace O-rings of A/C piping with new ones, and then apply compressor oil to it when installing
it.

Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.

Insert one-touch joint connection point securely until it clicks.

After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.

O-rings are different from low-pressure pipe 1 (high-pressure pipe 2) and low-pressure pipe 2
(high-pressure pipe 3). High- pressure flexible hose bracket mounting bolt
Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb)
RJIA2076E
RJIA0928E

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Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sen-
sor can be located in the same position.

When recharging refrigerant, check for leaks.
Removal and Installation of Expansion ValveAJS001BK
REMOVAL
1. Remove evaporator. Refer to ATC-156, "Removal and Installation of Evaporator" .
2. Remove mounting bolts, and then remove expansion valve. CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:

Replace O-rings of evaporator with new ones, and then apply compressor oil to it when installing
it.

O-rings are different from low-pressure pipe 1 (high-pressure pipe 2) and low-pressure pipe 2
(high-pressure pipe 3).

When recharging refrigerant, check for leaks. Low-pressure pipe 1 bracket mounting bolt
Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb)
RJIA1864E

ATC-158
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Revision: 2005 July 2005 FX
Checking for Refrigerant LeaksAJS00163
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector (SST: J-42220).
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorAJS00164
1. Check A/C system for leaks using the UV lamp and safety goggles (SST: J42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open-
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (SST: J43872) to prevent future mis- diagnosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionAJS00165
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm
2 , 50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J 41459).
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture’s
operating instructions).
6. With the engine still running, disconnect the injector tool from the service fitting. CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
8. Attach a blue label as necessary.

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Electronic Refrigerant Leak DetectorAJS00166
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C electrical leak
detector (SST) or equivalent. Ensure that the instrument is calibrated
and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
1. Position probe approximately 5 mm (3/16 in) away from point to be checked.
2. When testing, circle each fitting completely with probe.
3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec.
SHA196FA
SHA707EA
SHA706E
SHA708EA

ATC-160
REFRIGERANT LINES
Revision: 2005 July 2005 FX
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Stop engine.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm
2 , 50 psi) above 16 °C (61 °F). If less
than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16 °C (61 °F), leaks may not be detected since the system may not reach 345 kPa
(3.52 kg/cm
2 , 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet h) to the low-pressure side [evaporator drain hose i to shaft seal o (VK45DE) or n (VQ35DE)]. Refer to ATC-140,
"Components" . Perform a leak check for the following areas carefully. Clean the component to be
checked and move the leak detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.
Liquid tank
Check the refrigerant connection.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7-10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Mode door position: VENT (Ventilation)
c. Intake position: Recirculation
d. Temperature setting: Max cold
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Stop engine and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
SHA839E

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11. Before connecting recovery/recycling recharging equipment to vehicle, check recovery/recycling recharg-
ing equipment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover
refrigerant from equipment lines and then check refrigerant purity.
12. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant identifier.
13. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrig- erant identifier.
14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com- ponent if necessary.
15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
16. Perform A/C performance test to ensure system works properly.

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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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

BRAKE FLUID BR-9
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BRAKE FLUIDPFP:KN100
On-Board InspectionAFS001MV
LEVEL CHECK

Make sure the fluid level in reservoir tank is within the standard
(between MAX and MIN lines).

Visually check around reservoir tank for fluid leaks.

If fluid level is excessively low, check brake system for leaks.

If brake warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.
Drain and RefillAFS001MW
CAUTION:

Refill with new brake fluid “DOT3”.

Do not reuse drained brake fluid.

Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
when splashing it, immediately wipe off the area and wash away with water.

Before servicing, disconnect actuator connector or battery negative cable.
1. Connect a vinyl tube to each bleed valve.
2. Depress brake pedal, loosen each bleed valve, and gradually remove brake fluid.
3. Make sure there is no foreign material in reservoir tank, and refill with new brake fluid.
4. Rest foot on brake pedal. Loosen bleed valve. Slowly depress pedal until it stops. Tighten bleed valve. Release brake pedal.
Repeat this process a few times, then pause to add new brake
fluid to master cylinder. Continue until new brake fluid flows out.
Bleed Air. Refer to BR-10, "
Bleeding Brake System" .
SFIA1032E
BRA0007D
SBR995