caliper 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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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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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
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BR-4
PREPARATION
Revision: 2006 December 2006 FX35/FX45
PREPARATIONPFP:00002
Commercial Service ToolsNFS000LQ
Tool name Description
1.Flare nut crowfoot a: 10 mm (0.39 in) / 12 mm (0.47 in)
2.Torque wrench Installing each brake piping
Pin punch
Tip diameter: φ 4 mm (0.16 in) dia. Removing and installing reservoir tank
pin
Power tool Removing front and rear caliper
assembly, tires
S-NT360
ZZA0515D
PBIC0190E
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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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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
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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
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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
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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