INFINITI M35 2007 Factory Service Manual

BR-14
BRAKE MASTER CYLINDER
Revision: 2007 April2007 M35/M45
BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionNFS000S3
LEAK INSPECTION

Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and InstallationNFS000S4
CAUTION:

Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.

Never scratch the piston of master cylinder when installing/removing because the piston is
exposed. Check if any dust is not on the piston, and wash with brake fluid if needed.

Hold cylinder body when handing master cylinder. Never hold the piston because the piston might
be detached if pulled strongly.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect brake fluid level switch harness connector.
3. Disconnect master cylinder brake tubes, using a flare nut wrench.
4. Remove master cylinder mounting nuts and remove master cylinder assembly from vehicle.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Never reuse drained brake fluid.
1. Installation is in the reverse order of removal.
CAUTION:
Apply silicone grease to brake booster (to “A” position in
the figure) when installing master cylinder to brake booster.
2. Tighten brake tube flare nut to the specified torque using a flare
nut torque wrench. Refer to BR-11, "
Hydraulic Circuit" .
3. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleed-
ing Brake System" .
SFIA2847J

BRAKE MASTER CYLINDER
BR-15
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Revision: 2007 April2007 M35/M45
Disassembly and AssemblyNFS000S5
COMPONENTS
DISASSEMBLY
CAUTION:

Master cylinder cannot be disassembled.

Remove reservoir tank only when absolutely necessary.

When securing master cylinder assembly in a vise, be sure not to over-tighten.

When securing in a vise use copper plates or cloth to protect the flange.
1. Using a pin punch [commercial service tool: diameter approxi-
mately 4 mm (0.16 in)], remove mounting pin on reservoir tank.
2. Remove reservoir tank and grommet from cylinder body.
1. Reservoir cap 2. Oil strainer 3. Reservoir tank
4. Grommet 5. Pin 6. Master cylinder assembly
7. O-ring 8. Brake fluid level switch connector
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
: Apply brake fluid.
SFIA2955E
BRA0559D

BR-16
BRAKE MASTER CYLINDER
Revision: 2007 April2007 M35/M45
ASSEMBLY
CAUTION:

Never use mineral oils 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 to the grommet and attach it to the cylinder body.
CAUTION:
Do not reuse grommet.
2. Install reservoir tank onto the cylinder body.
3. Secure master cylinder assembly into a vise with a chamfered
pin insert hole on cylinder body facing upward.
4. Tilt reservoir tank as shown in the figure and insert mounting pin.
Return reservoir tank to a upright position when mounting pin
passes through the pinhole in the cylinder body. Push the
mounting pin to the opposite pinhole of the reservoir tank so that
it is the same conditions as the insertion side.
CAUTION:

Be sure to fix the flange part with the brake tube installa-
tion side of cylinder body up.

Do not reuse mounting pin.
PFIA0505J
BRA0559D

BRAKE BOOSTER
BR-17
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Revision: 2007 April2007 M35/M45
BRAKE BOOSTERPFP:47200
On-Board Inspection and ServiceNFS000S7
OPERATION CHECK
With engine stopped, change vacuum to atmospheric pressure by
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the
standard, make sure that clearance between brake pedal and floor
panel decreases.
AIR TIGHT CHECK

Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change vacuum to atmospheric pressure. Make sure that dis-
tance at intervals of 5 seconds 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.
BRA0037D
SBR365AA

BR-18
BRAKE BOOSTER
Revision: 2007 April2007 M35/M45
Removal and InstallationNFS000S8
COMPONENTS
CAUTION:

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 during installa-
tion, the dash panel may damage the threads.
REMOVAL
1. Remove cowl top. Refer to EI-18, "Removal and Installation" .
2. Remove brake master cylinder. Refer to BR-14, "
Removal and
Installation" .
3. Disconnect front left brake tube from ABS actuator and electric
unit (control unit). Refer to BR-11, "
Hydraulic Circuit" .
4. Remove vacuum hose from brake booster. Refer to BR-20,
"Components" .
5. Remove snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster from dash panel in engine room side.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle. At this time, make sure that a gasket
between booster assembly and dash panel is installed.
CAUTION:
Always install gasket between brake booster and dash
panel.
3. Connect brake pedal with clevis of input rod.
1. Master cylinder assembly 2. Brake booster 3. Lock nut
4. Brake pedal 5. Gasket
Refer to GI-11, "
Components" , for the symbols in the figure.
SFIA2956E
SFIA2044E
Length “B” : 125 mm (4.92 in)
SGIA0060E

BRAKE BOOSTER
BR-19
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Revision: 2007 April2007 M35/M45
4. Install brake pedal bracket mounting nuts and bolt, and tighten them to the specified torque. Refer to BR-
7, "COMPONENTS" .
5. Install vacuum hose into brake booster. Refer to BR-21, "
Removal and Installation" .
6. Install master cylinder to booster assembly. Refer to BR-14, "
Removal and Installation" .
7. Adjust the brake pedal height and the play of the brake pedal. Refer to BR-6, "
ADJUSTMENT" .
8. Tighten lock nut of input rod to the specified torque. Refer to BR-18, "
COMPONENTS" .
9. Connect front left brake tube to ABS actuator and electric unit (control unit). Refer to BR-11, "
Hydraulic
Circuit" .
10. Install cowl top. Refer to EI-18, "
Removal and Installation" .
11. Refill new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .

BR-20
VACUUM LINES
Revision: 2007 April2007 M35/M45
VACUUM LINESPFP:41920
ComponentsNFS000S9
VK45DE ENGINE MODELS
VQ35DE ENGINE MODELS
SFIA2957E
1. Clamp 2. Vacuum hose 3. Engine direction indicator stamp
(Built in check valve)
4. Clip 5. Vacuum piping 6. Grommet (Vacuum hose side)
7. Grommet (Cowl top assy side) 8. For intake manifold 9. For brake booster
SFIA2958E
1. Clamp 2. Vacuum hose 3. Engine direction indicator stamp
(Built in check valve)
4. Clip 5. Vacuum piping 6. Grommet (Vacuum hose side)
7. Grommet (Cowl top assy side) 8. For intake manifold 9. For brake booster

VACUUM LINES
BR-21
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Revision: 2007 April2007 M35/M45
Removal and InstallationNFS000SA
CAUTION:

Because vacuum hose contains a check valve, it must be
installed in the correct position. Refer to the stamp to con-
firm correct installation. Brake booster will not operate nor-
mally if the hose is installed in the wrong direction.

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

Do not use lubricating oil during assembly.
InspectionNFS000SB
VISUAL INSPECTION
Check for correct assembly, damage and deterioration.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.

Replace vacuum hose assembly if vacuum hose and check
valve are malfunctioning.
SBR225B
When connected to the booster side (1):
Vacuum should decrease within 1.3 kPa (10
mmHg, 0.39 inHg) for 15 seconds under a vacuum
of −66.7 kPa (−500 mmHg, −19.69 inHg).
When connected to the engine side (2):
Vacuum should not exist.
SFIA0210E

BR-22
FRONT DISC BRAKE
Revision: 2007 April2007 M35/M45
FRONT DISC BRAKEPFP:41000
On-Board InspectionNFS000SC
PAD WEAR INSPECTION

Check pad thickness from an inspection hole on cylinder body.
Check using a scale if necessary.
ComponentsNFS000SD
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:

While removing cylinder body, do not 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. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. 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.
PFIA0820E

FRONT DISC BRAKE
BR-23
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Revision: 2007 April2007 M35/M45

It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a 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 shim and shim cover as a set when replacing brake pads.

Keep rotor free from brake fluid.

Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-27, "
BRAKE
BURNISHING PROCEDURE" .
Removal and Installation of Brake PadNFS000SE
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, and shim cover from torque member.
CAUTION:
When removing the pad retainer from the torque member,
lift it in the direction indicated by the arrow in the figure so
that it does not deform.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to between pad and shim. Install shim,
shim cover, to pad.
2. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease to between pad retainer and pad. Install pad retainers
and pads to torque member.
CAUTION:

Securely assemble pad retainers so that they are not
being lifted up from torque member.

Both inner and outer pads have a pad return system on
the pad retainer. Install pad return lever securely to pad
wear sensor.
3. Install cylinder body to torque member.
CAUTION:
In the case of replacing a pad with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press piston.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-22, "
Components" .
5. Check front disc brake for drag.
6. Install tires to vehicle.
SBR556E
SBR557E