brake INFINITI FX35 2006 Service Manual

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

BRAKE BOOSTER BR-15
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Revision: 2006 December 2006 FX35/FX45
BRAKE BOOSTERPFP:47200
On-Vehicle ServiceNFS000M5
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 brake pedal is interval is approximately at intervals
5 seconds.
ComponentsNFS000OB
BRA0037D
SBR365AA
1. Reservoir tank 2. Master cylinder 3. Gasket
4. Brake booster
Refer to GI-11, "
Components" , for the symbols in the figure.
PFIA0817E

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

VACUUM LINES BR-17
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Revision: 2006 December 2006 FX35/FX45
VACUUM LINESPFP:41920
ComponentsNFS000OC
Removal and InstallationNFS000M7
CAUTION:

Because vacuum hose contains a check valve, it must be installed in the correct direction. Refer to
the stamp or label to confirm correct installation. The brake booster will not operate normally if
hose is installed in the wrong direction.

Insert vacuum hose for at least 24 mm (0.94 in).

Do not use lubricating oil during assembly.
1. Clamp 2. Vacuum hose 3. Clamp
4. Vacuum piping 5. Clamp 6. Engine direction indicator
7. Vacuum hose (Build in check valve) 8. Clamp 9. Brake booster
SFIA1134E
SBR225B

FRONT DISC BRAKE BR-19
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Revision: 2006 December 2006 FX35/FX45
FRONT DISC BRAKEPFP:41000
On-Vehicle InspectionNFS000M9
PAD WEAR INSPECTION

Check the thickness from check hole on cylinder body. Use a
scale for inspection if necessary.
ComponentsNFS000MA
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. Standard thickness : 11.0 mm (0.433 in)
Repair limit thickness : 2.0 mm (0.079 in)
MAA0439D
1. Brake hose 2. Union bolt 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Torque member mounting bolt 12. Sliding pin
13. Sliding pin boot 14. Bushing 15. Torque member
16. Inner shim cover 17. Inner shim 18. Inner pad
19. Pad wear sensor 20. Pad retainer 21. Outer pad
22. Outer shim 23. Outer shim cover
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.
: Apply brake fluid.
PFIA0809E

BR-20
FRONT DISC BRAKE
Revision: 2006 December 2006 FX35/FX45

It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, suspend cylinder body with 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.

Keep rotor clean, from brake fluid.

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 PadNFS000MB
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers, shims from torque member.
CAUTION:
When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow (shown in the fig-
ure) so as not to deform it.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) or equivalent to the both sides
of inner shim and outer shim, install inner shim to inner pad, and
outer shim and outer shim cover to outer pad.
2. Apply PBC (Poly Butyl Cuprysil) or equivalent to pad contact surface on pad retainer, and install pad retainers and pads to
torque member.
CAUTION:
Inner pad and outer pad have pad-return mechanism on
upper side of pad retainer. When installing pad to torque
member, be sure to install pad return lever to pad wear sen-
sor securely.
3. Install cylinder body to torque member. CAUTION:
When replacing pads with new ones, press in piston until pads can be installed. In this case, care-
fully monitor brake fluid level in reservoir tank because brake fluid will return to master cylinder
reservoir tank.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-19, "
Components" .
5. Secure disc rotor with wheel nuts. Depress brake pedal a few times until it gets a responsive touch.
6. Check brake for drag.
7. Install tires to vehicle.
Removal and Installation of Brake Caliper AssemblyNFS000MC
REMOVAL
1. Remove tires from vehicle with power tool.
2. Fasten disc rotor using wheel nut.
3. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
SBR556E
SBR557E

FRONT DISC BRAKE BR-21
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Revision: 2006 December 2006 FX35/FX45
4. Remove union bolts and torque member bolts, and remove brake caliper assembly from the vehicle.
5. Remove disc rotor. CAUTION:
Put matching marks on both disc rotor and wheel hub when
removing disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT3”.

Do not reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Align the matching marks of disc rotor and wheel hub, which were marked at the time of removal
when reusing disc rotor.
2. Install caliper assembly to vehicle, and tighten mounting bolts to the specified torque. Refer to BR-19,
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and grease on washer seats on steering
knuckle and mounting surface of torque member.
3. Install a projection of brake hose metal fitting by aligning with protrusions on cylinder body, and tighten union bolts to the specified torque. Refer to BR-19, "
Components" .
CAUTION:

Do not reuse copper washer for union bolts.

Assemble brake hose securely on caliper assembly.
4. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
5. Install tires to vehicle.
Disassembly and Assembly of Brake Caliper AssemblyNFS000MD
NOTE:
Do not remove torque member, brake pads, shims, shim cover and pad retainer, when disassembling or
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-20,
"Removal and Installation of Brake Caliper Assembly" .
2. Remove sliding pin bolts from cylinder body, and remove pad, shim, shim cover and pad retainer from torque member.
CAUTION:
When removing pad retainer from torque member, lift the
pad retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.
SFIA0140E
SBR556E

BR-22
FRONT DISC BRAKE
Revision: 2006 December 2006 FX35/FX45
3. Remove sliding pins and sliding pin boots from torque member.
4. Place a wooden block as shown in the figure, and blow air from union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
5. Using a flat-bladed screwdriver, remove piston seal from cylin- der body.
CAUTION:
Be careful not to damage cylinder inner wall.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

Check the inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cyl-
inder body.

Minor flaws caused by corrosion or a foreign material can be removed by polishing a surface of the inner
wall with a fine sandpaper. Replace cylinder body, if necessary.
To r q u e M e m b e r
Check for wear, cracks, and damage. If a malfunction is detected, replace the torque member.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
Sliding Pin, Sliding Pin Bolt, and Sliding Pin Boot
Check sliding pins and sliding pin boots for wear, damage, and cracks. If a malfunction is detected, replace
applicable part.
ASSEMBLY
1. Apply polyglycol ether based lubricant to the piston seal, and install them to the cylinder body.
CAUTION:
Do not reuse piston seal.
BRB0032D
SFIA0141E
SFIA2920E

FRONT DISC BRAKE BR-23
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Revision: 2006 December 2006 FX35/FX45
2. Apply rubber grease to piston boot. Cover the piston end with piston boot, and install cylinder side lip on piston boot properly
into groove on cylinder body.
CAUTION:
Do not reuse piston boot.
3. Apply brake fluid to piston, and press piston into cylinder body by hand to assemble piston side lip on piston boot properly into
groove on piston.
CAUTION:
Press piston evenly and vary the pressing point to prevent
cylinder inner wall from being rubbed.
4. Install sliding pins and sliding pin boots to torque member.
5. Install the torque member to the knuckle spindle and tighten the mounting bolts to the specified torque. Refer to BR-19, "
Compo-
nents" .
CAUTION:
Before installing torque member to vehicle, wipe oil and
grease on the washer seats on steering knuckle and the
mounting surface of the torque member.
6. Install pad retainers to torque member.
7. After assembling shims and shim covers to pad, install it to torque member.
CAUTION:
Inner pad and outer pad have pad-return mechanism on the upper side of the pad retainer. When
installing pad, be sure to install pad return lever to pad wear sensor securely as shown in the fig-
ure.
8. Install cylinder body, and tighten sliding pin bolt to specified torque. Refer to BR-19, "
Components" .
9. Install a projection of brake hose metal fitting by aligning with protrusions on cylinder body, and then tighten union bolts to specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:

Assemble brake hose securely to protrusions on cylinder body.

Do not reuse copper washer for union bolts.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
SFIA2432E
SFIA2279E
SBR557E

BR-24
FRONT DISC BRAKE
Revision: 2006 December 2006 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 wheels hub. (2 or more positions)
2. Using a dial indicator, check runout.
CAUTION:
Before measuring, make sure that axle end play is 0.05 mm
(0.002 in) or less.
3. If runout is outside the limit, find the minimum runout point by shifting the mounting positions of disc rotor and wheel hub by
one hole.
4. If runout is 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 specification, replace disc rotor.
Brake Burnishing ProcedureNFS000OD
Burnish brake pad contact surfaces of disc rotor according to following procedure after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because brake does not operate easily until pad and disc rotor are
securely fitted.

Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.
3. Drive without depressing brake for a few minutes to cool brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted. Measurement point
: At a point 10.0 mm (0.394 in)
from outer edge of disc.
Runout limit : 0.04 mm (0.0016 in) or less
SBR019B
Standard thickness : 34.0 mm (1.339 in)
Wear limit : 32.0 mm (1.260 in)
Maximum uneven wear
(measured at 8 positions) : 0.015 mm (0.0006 in)
or less
SBR020B