brake rotor INFINITI M35 2007 Factory Service Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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M
SECTION BR
A
B
BR
Revision: 2007 April2007 M35/M45
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
ADJUSTMENT ...................................................... 6
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
On-Board Inspection ................................................ 9
CHECKING BRAKE FLUID LEVEL ...................... 9
Checking Brake Line ................................................ 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 ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Tube and
Brake Hose ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
Inspection after Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-Board Inspection .............................................. 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Disassembly and Assembly .................................... 15
COMPONENTS ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
BRAKE BOOSTER ................................................... 17
On-Board Inspection and Service ........................... 17
OPERATION CHECK .......................................... 17
AIR TIGHT CHECK ............................................. 17
Removal and Installation ........................................ 18
COMPONENTS ................................................... 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 18
VACUUM LINES ....................................................... 20
Components ........................................................... 20
Removal and Installation ........................................ 21
Inspection ............................................................... 21
VISUAL INSPECTION ......................................... 21
CHECK VALVE INSPECTION ............................. 21
FRONT DISC BRAKE ............................................... 22
On-Board Inspection ............................................... 22
PAD WEAR INSPECTION ................................... 22
Components ........................................................... 22
Removal and Installation of Brake Pad .................. 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
Removal and Installation of Brake Caliper Assembly
... 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 25
DISASSEMBLY ................................................... 25
INSPECTION AFTER DISASSEMBLY ................ 25
ASSEMBLY ......................................................... 26
DISC ROTOR INSPECTION ............................... 27
BRAKE BURNISHING PROCEDURE ................. 27
REAR DISC BRAKE ................................................. 28
On-Board Inspection ............................................... 28

BR-2Revision: 2007 April2007 M35/M45 PAD WEAR INSPECTION ................................... 28
Components ........................................................... 28
Removal and Installation of Brake Pad ................... 29
REMOVAL ........................................................... 29
INSTALLATION .................................................... 29
Removal and Installation of Brake Caliper Assembly
... 30
REMOVAL ........................................................... 30
INSTALLATION .................................................... 30
Disassembly and Assembly of Brake Caliper Assembly ................................................................ 31
DISASSEMBLY .................................................... 31
INSPECTION AFTER DISASSEMBLY ................ 31
ASSEMBLY .......................................................... 32
DISC ROTOR INSPECTION ............................... 33
BRAKE BURNISHING PROCEDURE ................. 33
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
General Specifications ............................................ 34
Brake Pedal ............................................................ 34
Brake Booster ......................................................... 34
Check Valve ............................................................ 34
Front Disc Brake ..................................................... 34
Rear Disc Brake ...................................................... 34

PRECAUTIONS
BR-3
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D
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K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NFS000RO
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 CoverNFS000RP
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precautions for Brake SystemNFS000RQ

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”. Refer to MA-12, "Fluids and Lubricants" .

Never reuse drained brake fluid.

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.

Use clean brake fluid, to clean or wash all parts of master cylinder and disc brake caliper, etc.

Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

Use flare nut torque wrench when installing brake tube.

When installing brake tube and hose, be sure to check torque.

Before working, turn ignition switch OFF and disconnect con-
nectors of ABS actuator and electric unit (control unit) or battery
cable from the negative terminal.

Burnish the brake contact 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 PROCE-
DURE" (front disc brake), BR-33, "BRAKE BURNISHING PRO-
CEDURE" (rear disc brake).
WARNING:

Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
PIIB3706J
SBR686C

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
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D
E
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H
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K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNFS000RS
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: Applicable Reference page
BR-22
, BR-28
BR-22
, BR-28

BR-22
, BR-28

—
—
BR-27
, BR-33

—
—
—
BR-27
, BR-33

—
NVH in PR section
NHV in FFD and RFD section
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in FAX and RAX section
NVH in PS section
Possible cause and
SUSPECTED PARTS
Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
Symptom BRAKENoise××× ×× ×××
××
Shake×××××
××
Shimmy, Judder××××××× ××× ×

FRONT DISC BRAKE
BR-23
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D
E
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H
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J
K
L
MA
B
BR
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

BR-24
FRONT DISC BRAKE
Revision: 2007 April2007 M35/M45
Removal and Installation of Brake Caliper AssemblyNFS000SF
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" .
4. Remove union bolt, and then disconnect brake hose from caliper assembly.
5. Remove torque member mounting bolts, and remove brake cali-
per assembly.
CAUTION:
Do not drop brake pad.
6. Remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it is necessary to remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Never reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Put alignment marks on disc rotor and wheel hub at the time of removal when reusing disc rotor.
2. Install brake caliper assembly to vehicle, and tighten torque member mounting bolts to the specified
torque. Refer to BR-22, "
Components" .
CAUTION:
Do not allow oil or any moisture on all contact surfaces between steering knuckle and caliper
assembly, bolts, and washer.
3. Install brake hose to brake caliper assembly, and tighten union
bolts to the specified torque. Refer to BR-12, "
Removal and
Installation of Front Brake Tube and Brake Hose" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleed-
ing Brake System" .
5. Check front disc brake for drag.
6. Install tires to vehicle.
SFIA2437E
SDIA2608E
SFIA2431E

FRONT DISC BRAKE
BR-27
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MA
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BR
Revision: 2007 April2007 M35/M45
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are.
Runout Inspection
1. Fix disc rotor to wheel hub using wheel nuts (2 or more posi-
tions).
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside the disc edge.]
NOTE:
Before measuring, make sure that wheel bearing axial end play
is within the specification. Refer to FAX-5, "
WHEEL BEARING
INSPECTION" .
3. When runout exceeds limit value, displace mounting positions of
disc rotor by one hole. And then find a position of the minimum value for runout.
4. Replace or lathe disc rotor if runout is outside the specified value after performing the above operation.
(“MAD DL-8700”, “AMMCO 700 and 705” or equivalent.)
Thickness Inspection
Check thickness of the disc rotor using a micrometer. Replace disc
rotor if thickness is under the wear limit.
BRAKE BURNISHING PROCEDURE
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because the 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 the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.Runout limit : 0.035 mm (0.0014 in)
(with it attached to the vehicle)
BRA0580D
Standard thickness : 28.0 mm (1.102 in)
Wear limit : 26.0 mm (1.024 in)
Thickness variation
(Measured at 8 positions): 0.015 mm (0.0006 in)
SBR020B

REAR DISC BRAKE
BR-29
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MA
B
BR
Revision: 2007 April2007 M35/M45
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.

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 covers 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-33, "
BRAKE
BURNISHING PROCEDURE" .
Removal and Installation of Brake PadNFS000SJ
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 mem-
ber.
CAUTION:
Deform pad retainer when removing pad retainer from torque member.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to between pad and shim. Install inner
shim, inner shim cover to inner pad, and outer shim, outer shim cover to outer pad.
2. Install pad retainers and pads to torque member.
3. Press in piston until pads can be installed, and then install cylin-
der 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 upper sliding pin bolt and tighten to the specified torque.
Refer to BR-28, "
Components" .
5. Check rear disc brake for drag.
6. Install tires to vehicle.
3: Apply polyglycol ether based lubricant.
: Apply brake fluid.
PFIA0273E

BR-30
REAR DISC BRAKE
Revision: 2007 April2007 M35/M45
Removal and Installation of Brake Caliper AssemblyNFS000SK
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" .
4. Remove union bolt and then disconnect brake hose from caliper
assembly.
5. Remove torque member mounting, bolts, and remove brake cal-
iper assembly.
CAUTION:
Do not drop brake pad.
6. Remove disc rotor.
CAUTION:
Put matching marks on wheel hub assembly and disc rotor,
if it necessary to remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Never reuse drained brake fluid.
1. Install disc rotor.
CAUTION:
Alignment marks of disc rotor and wheel hub put at the time of removal when reusing disc rotor.
2. Install brake caliper assembly vehicle, and tighten torque member mounting bolts to the specified torque.
Refer to BR-28, "
Components" .
CAUTION:
Before installing caliper assembly, wipe off oil and moisture on all mounting surfaces of rear axle
and caliper assembly and threads, bolts and washers.
3. Install L-shaped pin of brake hose and then tighten union bolt to
the specified torque. Refer to BR-12, "
Removal and Installation
of Rear Brake Tube and Brake Hose" .
4. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleed-
ing Brake System" .
5. Check rear disc brake for drag.
6. Install tires to vehicle.
SFIA2972E
SDIA2638E
SFIA2049E

REAR DISC BRAKE
BR-33
C
D
E
G
H
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J
K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace if there are.
Runout Inspection
1. Fix disc rotor to wheel hub using wheel nuts (2 or more posi-
tions).
2. Inspect runout using dial gauge. [Measured at 10 mm (0.39 in)
inside disc edge.]
NOTE:
Before measuring, make sure that wheel bearing axial end play
is within the specification. Refer to RAX-5, "
WHEEL BEARING
INSPECTION" .
3. When runout exceeds limit value, displace mounting positions of
disc rotor by one hole. And then find a position of the minimum value for runout.
4. Replace disc rotor if it is outside repair limit after performing the above operation.
Thickness Inspection
Check the thickness of the disc rotor using a micrometer. Replace
disc rotor if the thickness is under the wear limit.
BRAKE BURNISHING PROCEDURE
Burnish contact surfaces between disc rotors and pads according to following procedure after refinishing or
replacing rotors, after replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:

Be careful of vehicle speed because the 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 the vehicle on a 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 the brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.Runout limit : 0.055 mm (0.0022 in)
(With it attached to the vehicle)
BRA0697D
Standard thickness : 16.0 mm (0.631 in)
Wear limit : 14.0 mm (0.551 in)
Thickness variation
(Measured at 8 positions): 0.015 mm (0.0006in)
SFIA2284E