air bleeding INFINITI FX35 2008 Service Manual

BR-1
BRAKES
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CONTENTS
BRAKE SYSTEM
SERVICE INFORMATION .. ..........................2
PRECAUTIONS .............................................. .....2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
2
Precaution for Procedure without Cowl Top Cover ......2
Precaution for Brake System ....................................2
PREPARATION ...................................................3
Commercial Service Tool .................................... ......3
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .............................
4
NVH Troubleshooting Chart ................................ ......4
BRAKE PEDAL .............................................. .....5
Inspection and Adjustment .................................. ......5
Component ................................................................6
Removal and Installation ...........................................6
BRAKE FLUID .....................................................8
On-Board Inspection ........................................... ......8
Drain and Refill ..........................................................8
Bleeding Brake System .............................................8
BRAKE TUBE AND HOSE ................................10
Hydraulic Circuit .................................................. ....10
Removal and Installation of Front Brake Tube and
Brake Hose .............................................................
10
Removal and Installation of Rear Brake Piping
and Brake Hose ......................................................
11
Inspection After Installation .....................................11
BRAKE MASTER CYLINDER ........................ ....12
On-Board Inspection ........................................... ....12
Component ..............................................................12
Removal and Installation .........................................12
Disassembly and Assembly ....................................13
BRAKE BOOSTER ...........................................14
On-Vehicle Service .............................................. ....14
Component ..............................................................14
Removal and Installation .........................................14
VACUUM LINES ...............................................16
Component ..............................................................16
Removal and Installation .........................................16
Inspection ................................................................16
FRONT DISC BRAKE .......................................18
On-Vehicle Inspection ......................................... ....18
Component ..............................................................18
Removal and Installation of Brake Pad ...................19
Removal and Installation of Brake Caliper Assem-
bly ........................................................................ ....
19
Disassembly and Assembly of Brake Caliper As-
sembly .....................................................................
20
Brake Burnishing Procedure ....................................23
REAR DISC BRAKE .........................................24
On-Vehicle Inspection ......................................... ....24
Component ..............................................................24
Removal and Installation of Brake Pad ...................25
Removal and Installation of Brake Caliper Assem-
bly ........................................................................ ....
25
Disassembly and Assembly of Brake Caliper As-
sembly .....................................................................
26
Brake Burnishing Procedure ....................................29
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
30
General Specification ..............................................30
Brake Pedal .............................................................30
Brake Booster ..........................................................30
Check Valve ............................................................30
Front Disc Brake ......................................................30
Rear Disc Brake ......................................................30
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
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BR-8
< SERVICE INFORMATION >
BRAKE FLUID
BRAKE FLUID
On-Board InspectionINFOID:0000000001327610
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 leakage.
 If fluid level is excessively low, check brake system for leakage.
 Release parking brake pedal and see if brake warning lamp goes off. If not, check brake system for fluid leakage.
Drain and RefillINFOID:0000000001327611
CAUTION:
 Refill with new brake fluid “DOT3”.
 Do not reuse drained brake fluid.
 Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of bo dy, immediately wipe it off and them wash it away with water
immediately.
 Before working, disconnect connectors of ABS actua tor and electric unit (control unit) or battery
negative terminal.
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 bl eed 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.
5. Bleed Air. Refer to BR-8, "
Bleeding Brake System".
Bleeding Brake SystemINFOID:0000000001327612
CAUTION:
SFIA1032E
BRA0007D
SBR995
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3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C

BRAKE FLUIDBR-9
< SERVICE INFORMATION >
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 Carefully monitor brake fluid level in reservoir tank during bleeding operation.
 Refill with new brake fluid “DOT 3”. Make sure it is at least half
way at all times while bleeding air out of system.
 Place a container under master cylinder not to spill brake fluid.
 Turn ignition switch OFF and disconnect ABS actuator and
electric unit (control unit) or battery negative terminal.
 Bleed air in the following order. Right rear brake → Left front
brake → Left rear brake → Right front brake
1. Connect a transparent vinyl tube to bleed valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open bleed valve to release air.
4. Close bleed valve.
5. Release brake pedal slowly.
6. Repeat steps 2, through 5, until clear brake fluid comes out of bleed valve.
SBR995
SBR419C
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BR-10
< SERVICE INFORMATION >
BRAKE TUBE AND HOSE
BRAKE TUBE AND HOSE
Hydraulic CircuitINFOID:0000000001327613
CAUTION:
 All brake hoses and tubes must be free from excessive bending, twisting and pulling.
 Make sure there is no interference with other part s when turning steering both clockwise and coun-
terclockwise.
 The brake tubes and hoses is an important safety pa rt. If a brake fluid leak is detected, always disas-
semble 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 bo dy, 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 br ake line connections so that no dirt, no dust, or other foreign
matter gets in.
 Refill with new brake fluid “ DOT 3 ”.
 Do not reuse drained brake fluid.
Removal and Installation of Fr ont Brake Tube and Brake HoseINFOID:0000000001327614
REMOVAL
1. Drain brake fluid. Refer to BR-8, "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-8, "
Bleeding Brake
System".
PFIA0818E
SFIA1204E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C

BRAKE TUBE AND HOSEBR-11
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Removal and Installation of R ear Brake Piping and Brake HoseINFOID:0000000001327615
REMOVAL
1. Drain brake fluid. Refer to BR-8, "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 positioni ng hole and then tighten union bolt to the specified torque.
Refer to BR-10, "
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.
3. Tighten brake hose mounting bolt to the specified torque.
4. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-10, "
Hydraulic Circuit".
5. After installation, bleed air. Refer to BR-8, "
Bleeding Brake Sys-
tem".
Inspection After InstallationINFOID:0000000001327616
CAUTION:
If a leak is detected at the connections, re tighten 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.
SFIA1942E
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BRAKE MASTER CYLINDERBR-13
< SERVICE INFORMATION >
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5. Remove master cylinder assembly mounting nut, re move master cylinder assembly from the vehicle.
Refer to BR-14, "
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 tight en mounting nuts to the specified torque. Refer to BR-14,
"Component".
2. Refill brake fluid and bleed air. Refer to BR-8, "
Bleeding Brake System".
Disassembly and AssemblyINFOID:0000000001327620
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, g asoline 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
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BRAKE BOOSTERBR-15
< SERVICE INFORMATION >
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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 thr eads. If brake booster is tilted or inclined during
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-16
.
2. Remove brake master cylinder. Refer to BR-12, "
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-6, "
Component".
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 r od 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-6, "
Component".
5. Install brake tube from brake master cylinder to ABS actuator. Refer to BR-10, "
Hydraulic Circuit".
6. Install master cylinder to booster assembly. Refer to BR-12, "
Removal and Installation".
7. Adjust the height and play of brake pedal. BR-5, "
Inspection and Adjustment".
8. Tighten lock nut of input rod to the specified torque. Refer to BR-14, "
Component".
9. Bleed air. Refer to BR-8, "
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
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BR-20
< SERVICE INFORMATION >
FRONT DISC BRAKE
4. Remove union bolts and torque member bolts, and removebrake 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-18,
"Component".
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-18, "
Component".
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-8, "
Bleeding Brake
System".
5. Install tires to vehicle.
Disassembly and Assembly of Brake Caliper AssemblyINFOID:0000000001327631
NOTE:
Do not remove torque member, brake pads, shims, shim covers and pad retainers, when disassembling or
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-19,
"Removal and Installation of Brake Caliper Assembly".
2. Remove sliding pin bolts from cylinder body, and remove pads, shims, shim covers and pad retainers from torque member.
CAUTION:
When removing pad retainer fr om torque member, lift the
pad retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.
SFIA0140E
SBR556E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
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BR-22
< SERVICE INFORMATION >
FRONT DISC BRAKE
2. Apply rubber grease to piston boot. Cover the piston end withpiston 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-18, "
Compo-
nent".
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 figure.
8. Install cylinder body, and tighten sliding pin bolt to specified torque. Refer to BR-18, "
Component".
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-10, "
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-8, "
Bleeding Brake
System".
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)
SFIA2432E
SFIA2279E
SBR557E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
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BR-26
< SERVICE INFORMATION >
REAR DISC BRAKE
CAUTION:
 Refill with new brake fluid “DOT 3”.
 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 the vehicle, and tighten bolts to the specified torque. Refer to BR-24, "
Compo-
nent".
CAUTION:
Before installing caliper assembly to the vehicle , wipe off oil and grease on washer seats on axle
assembly and mounting surface of caliper assembly.
3. Install brake hose to caliper assembly and tighten union bolt to the specified torque. Refer to BR-24,
"Component".
CAUTION:
 Do not reuse copper washer for union bolts.
 Securely install brake hose to protrusion on caliper assembly.
4. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-8, "
Bleeding Brake
System".
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper AssemblyINFOID:0000000001327637
NOTE:
Do not remove torque member, brake pads, shims, shim cover and pad retainers, when disassembling or
assembling cylinder body.
DISASSEMBLY
1. Remove sliding pin bolts, and then remove brake pads, shims, shim cover, and pad retainer from torque
member and cylinder.
CAUTION:
Do not drop brake pads, shims, shim cover and pad retainer from torque member.
2. Remove sliding pin boot from torque member.
3. As shown in the figure, using a flat-bladed screwdriver, remove retaining ring from cylinder body.
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.
SBR028A
BRD0041D
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