removal INFINITI FX35 2006 Service Manual
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2006, Model line: FX35, Model: INFINITI FX35 2006Pages: 4462, PDF Size: 57.74 MB
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BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
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BR
Revision: 2006 December 2006 FX35/FX45
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 ................................................. ..... 6
Components ........................................................ ..... 7
Removal and Installation ..................................... ..... 7
REMOVAL ........................................................ ..... 7
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 TUBE AND HOSE .................................... ....11
Hydraulic Circuit .................................................. .... 11
Removal and Installation of Front Brake Tube 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
Components ........................................................ ... 13
Removal and Installation ..................................... ... 13
REMOVAL ........................................................ ... 13
INSTALLATION ................................................ ... 14
Disassembly and Assembly ................................. ... 14
DISASSEMBLY ................................................ ... 14
ASSEMBLY ...................................................... ... 14
BRAKE BOOSTER ................................................ ... 15
On-Vehicle Service .............................................. ... 15
OPERATING CHECK ....................................... ... 15
AIRTIGHT CHECK ........................................... ... 15
Components ........................................................ ... 15
Removal and Installation ..................................... ... 16
REMOVAL ........................................................ ... 16
INSPECTION AFTER REMOVAL .................... ... 16
INSTALLATION ................................................ ... 16
VACUUM LINES .................................................... ... 17
Components ........................................................ ... 17
Removal and Installation ..................................... ... 17
Inspection ............................................................ ... 18
VISUAL INSPECTION ...................................... ... 18
CHECK VALVE INSPECTION .......................... ... 18
FRONT DISC BRAKE ............................................ ... 19
On-Vehicle Inspection .......................................... ... 19
PAD WEAR INSPECTION ................................ ... 19
Components ........................................................ ... 19
Removal and Installation of Brake Pad ............... ... 20
REMOVAL ........................................................ ... 20
INSTALLATION ................................................ ... 20
Removal and Installation of Brake Caliper Assembly ... 20
REMOVAL ........................................................ ... 20
INSTALLATION ................................................ ... 21
Disassembly and Assembly of Brake Caliper
Assembly ............................................................. ... 21
DISASSEMBLY ................................................ ... 21
INSPECTION AFTER DISASSEMBLY ............. ... 22
ASSEMBLY ...................................................... ... 22
Page 1102 of 4462
BR-2Revision: 2006 December 2006 FX35/FX45 DISC ROTOR INSPECTION ............................
... 24
Brake Burnishing Procedure ................................ ... 24
REAR DISC BRAKE .............................................. ... 25
On-Vehicle Inspection .......................................... ... 25
PAD WEAR INSPECTION ................................ ... 25
Components ........................................................ ... 25
Removal and Installation of Brake Pad ................ ... 26
REMOVAL ........................................................ ... 26
INSTALLATION ................................................. ... 26
Removal and Installation of Brake Caliper Assembly ... 27
REMOVAL ........................................................ ... 27
INSTALLATION ................................................. ... 27
Disassembly and Assembly of Brake Caliper Assembly .............................................................
... 27
DISASSEMBLY ................................................. ... 27
INSPECTION AFTER DISASSEMBLY ............. ... 28
ASSEMBLY ....................................................... ... 29
DISC ROTOR INSPECTION ............................ ... 31
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
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PRECAUTIONS BR-3
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BR
Revision: 2006 December 2006 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NFS000LN
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 CoverNFS000LO
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precautions for Brake SystemNFS000LP
Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air.
Recommended fluid is brake fluid “DOT 3”. MA-12, "Fluids and Lubricants" .
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 new brake fluid.
Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
Use a flare nut torque wrench when 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
cables.
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" (Front disc
brake), BR-31, "
Brake Burnishing Procedure" (Rear disc brake).
WARNING:
Clean brake pads and shoes with a waste cloth, then clean with a dust collector.
PIIB3706J
SBR686C
Page 1107 of 4462
BRAKE PEDAL BR-7
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Revision: 2006 December 2006 FX35/FX45
ComponentsNFS000OA
Removal and InstallationNFS000LT
REMOVAL
1. Remove front kicking plate (driver side). Refer to EI-39, "KICKING PLATE" .
2. Remove dash side finisher (driver side). Refer to EI-38, "
DASH SIDE FINISHER" .
3. Remove instrument lower panel (driver side). Refer to IP-13, "
(K) Instrument Driver 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 bolt from bracket, and remove brake pedal assembly from vehicle.
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 ICC)
7. Stop lamp switch 8. Clip
SFIA1940E
SFIA0159E
Page 1108 of 4462
BR-8
BRAKE PEDAL
Revision: 2006 December 2006 FX35/FX45
INSPECTION AFTER REMOVAL
Make sure the rivets in the upper part of brake pedal are not
deformed.
Make sure that joint length “L” of sub-bracket and sliding plate is
5.5 mm (0.217 in) or more.
Replace brake pedal assembly if any non-standard condition is
detected.
Check clevis pin and plastic stopper for damage and deforma-
tion. Replace clevis pin if there are.
INSTALLATION
Installation in the reverse order of removal.
After installing brake pedal assembly to the vehicle, adjust brake pedal height. Refer to BR-6, "Inspection
and Adjustment" .
SFIA2487E
SBR997
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BRAKE TUBE AND HOSE BR-11
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Revision: 2006 December 2006 FX35/FX45
BRAKE TUBE AND HOSEPFP:46210
Hydraulic CircuitNFS000LX
CAUTION:
All brake hoses and tubes must be free from excessive bending, twisting and pulling.
Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.
The brake tubes and hoses is an important safety part. If a brake fluid leak is detected, always dis-
assemble the parts. Replace applicable part with a new one, if necessary.
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water
immediately.
Do not bend or twist brake hose sharply, or strongly pull it.
When removing components, cover brake line connections so that no dirt, no dust, or other for-
eign matter gets in.
Refill with new brake fluid “ DOT 3 ”.
Do not reuse drained brake fluid.
Removal and Installation of Front Brake Tube and Brake Hose NFS000LY
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from caliper assembly.
4. Remove lock plate and remove brake hose from vehicle.
INSTALLATION
1. Position brake hose by aligning with the protrusion on caliper assembly, and them tighten union bolt to the specified torque.
CAUTION:
Do not reuse copper washer.
2. Install brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Secure them it to bracket with lock
plate.
3. Using a flare nut torque wrench, tighten flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
PFIA0818E
SFIA1204E
Page 1112 of 4462
BR-12
BRAKE TUBE AND HOSE
Revision: 2006 December 2006 FX35/FX45
Removal and Installation of Rear Brake Piping and Brake Hose NFS000LZ
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt, and then remove brake hose from caliper assembly.
4. Remove lock nut plate and remove brake hose from vehicle.
INSTALLATION
1. Install brake hose to caliper assembly positioning hole and then tighten union bolt to the specified torque. Refer to BR-11,
"Hydraulic Circuit" .
CAUTION:
Do not reuse copper washer.
2. Connect brake hose to brake tube. Temporarily tighten flare nut by hand as much as possible. Tighten it to the specified torque.
3. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-11, "
Hydraulic Circuit" .
4. After installation, bleed air. Refer to BR-10, "
Bleeding Brake System" .
Inspection After InstallationNFS000M0
CAUTION:
If a leak is detected at the connections, retighten it or replace damaged part if necessary.
1. Check brake lines (tubes and hoses), and connections for fluid leakage, damage, twist, deformation, con- tact with other parts, and loose connections.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately 5 seconds, check for fluid leak from each part. : 23.5 N·m (2.4 kg-m, 17 ft-lb)
SFIA1942E
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BRAKE MASTER CYLINDER BR-13
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Revision: 2006 December 2006 FX35/FX45
BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionNFS000M1
LEAK INSPECTION
Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
ComponentsNFS000M3
Removal and InstallationNFS000M2
CAUTION:
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water imme-
diately.
REMOVAL
1. Remove cowl top cover. Refer to EI-23, "COWL TOP" .
2. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
3. Remove harness connectors for fluid level sensor and pressure sensor.
4. Using a flare nut wrench, remove brake tube from master cylinder assembly.
1. Reservoir cap 2. Strainer 3. Reservoir tank
4. Grommet 5. Cylinder body 6. Pin
7. Pressure sensor 8. Pressure sensor (Only ICC models)
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
: Apply brake fluid.
PFIA0815E
Page 1114 of 4462
BR-14
BRAKE MASTER CYLINDER
Revision: 2006 December 2006 FX35/FX45
5. Remove master cylinder assembly mounting nut, remove master cylinder assembly from the vehicle. Refer to BR-16, "
Removal and Installation" .
INSTALLATION
CAUTION:
Refill with new brake fluid “DOT3”.
Do not reuse drained brake fluid.
1. Install in the reverse order of removal, and tighten mounting nuts to the specified torque. Refer to BR-15,
"Components" .
2. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
Disassembly and AssemblyNFS000M4
DISASSEMBLY
CAUTION:
Master cylinder can not be disassembled.
Remove reservoir tank only when absolutely necessary.
1. Remove pin (1).
2. Remove reservoir tank and grommet from master cylinder assembly.
ASSEMBLY
CAUTION:
Do not use mineral oil such as kerosene, gasoline during the cleaning and assembly process.
Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid grommet and attach to master cylinder assembly. CAUTION:
Do not reuse grommet.
Do not reuse pin.
2. Install reservoir tank onto master cylinder assembly.
3. Install pin (1).
PFIA0816E
PFIA0816E
Page 1116 of 4462
BR-16
BRAKE BOOSTER
Revision: 2006 December 2006 FX35/FX45
Removal and InstallationNFS000M6
REMOVAL
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off and them wash it away with water
immediately.
Be careful not to deform or bend brake tube while removing and installing brake booster.
Replace clevis pin if it is damaged.
Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, dash panel may damage the threads.
Install the check valve in the correct direction.
1. Remove vacuum hose from brake booster. Refer to BR-17, "
VACUUM LINES" .
2. Remove brake master cylinder. Refer to BR-13, "
Removal and Installation" .
3. Disconnect harness connector from brake booster assembly. (ICC model)
4. Remove snap pin and clevis pin from inside the vehicle. Refer to BR-7, "
Components" .
5. Remove nuts from brake booster and brake pedal bracket.
6. Remove brake booster assembly from engine room.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of –66.7 kPa (– 500 mmHg, –19.69 inHg) to brake booster.
2. Check output rod length.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length “B” (shown in the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install brake booster assembly to the vehicle. At this time, make sure to
install a gasket between brake booster assembly and the engine
room.
3. Connect brake pedal with clevis of input rod.
4. Install brake pedal bracket mounting nuts and bolt and tighten them to the specified torque. BR-7, "
Components" .
5. Install brake tube from brake master cylinder to ABS actuator. Refer to BR-11, "
Hydraulic Circuit" .
6. Install master cylinder to booster assembly. Refer to BR-13, "
Removal and Installation" .
7. Adjust the height and play of brake pedal. BR-6, "
Inspection and Adjustment" .
8. Tighten lock nut of input rod to the specified torque. Refer to BR-15, "
Components" .
9. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
Standard dimension when applying a vacuum of
− 66.7 kPa ( −500 mmHg, −19.69 inHg):
15.6 − 15.9 mm (0.614 − 0.626 in)
SFIA2146E
Length “B” : 126.5 mm (4.98 in)
SGIA0060E