brake rotor INFINITI QX4 2005 Factory Service Manual

QUICK REFERENCE CHART: QX56
2005

Rear Wheel AlignmentELS001U6
BrakeELS001U7
Unit: mm (in) Camber
Degree minute (decimal degree)Minimum 0° 0′ (0°)
Nominal - 0° 30′ (-0.5°)
Maximum - 1° 0′ (-1.0°)
Cross camber 0° 45′ (0.75°)
To e - i nDistance (A - B)Minimum 0 mm (0 in)
Nominal 3.3 mm (0.130 in)
Maximum 6.6 mm (0.260 in)
Cross toe 2 mm (0.079 in)
Angle (left, right)
Degree minute (decimal
degree)Minimum 0° 0′ (0°)
Nominal 0° 7′ (0.11°)
Maximum 0° 14′ (0.22°)
Cross toe 0° 8′ (0.14°)
SFA234AC
Front brake Brake model CLZ31VC
Rotor outer diameter × thickness 320 × 26 (12.60 × 1.02)
Pad Length × width × thickness 111.0 × 73.5 × 9.5 (4.73 × 2.894 × 0.374)
Cylinder bore diameter 51 (2.01)
Rear brake Brake model AD14VE
Rotor outer diameter × thickness 320 × 14 (12.60 × 0.55)
Pad Length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Cylinder bore diameter 48 (1.89)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
Diaphragm diameter 215 (8.46)
Recommended brake fluidGenuine NISSAN Super Heavy Duty Brake Fluid or equivalent,
DOT 3 (US FMVSS No. 116)

2005
QUICK REFERENCE CHART: QX56

Disc Brake - Repair LimitsELS001U8
Unit: mm (in)
Brake PedalELS001U9
Unit: mm (in)
Refill CapacitiesELS001UA
Brake model CLZ31VC (Front) AD14VE (Rear)
Brake PadStandard thickness (new) 11.88 (0.468) 12.13 (0.478)
Repair limit thickness 1.0 (0.039) 1.0 (0.039)
Disc rotorStandard thickness (new) 26.0 (1.024) 14.0 (0.551)
Repair limit thickness 24.5 (0.965) 12.0 (0.472)
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.04 (0.0016) 0.05 (0.0020)
Brake pedal height (from dash panel top surface) 182.3 − 192.3 (7.18 − 7.57)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb) with engine running] More than 90.3 (3.55)
Clearance between stopper rubber and the threaded end of stop lamp switch 0.74 − 1.96 (0.029 − 0.077)
Pedal play3 − 11 (0.12 − 0.43)
DescriptionCapacity (Approximate)
Metric US measure Imp measure
Fuel
105.8 28 US gal 23 1/4 Imp gal
Engine oil
Drain and refillWith oil filter change
6.2 6 1/2 qt 5 1/2 qt
Without oil filter change
5.9 6 1/4 qt 5 1/4 qt
Dry engine (engine overhaul)
7.6 8 qt 6 3/4 qt
Cooling system With reservoir at MAX level
14.4 3 3/4 gal 3 1/8 gal
Automatic transmission fluid (ATF)
10.6 11 1/4 qt 9 3/8 qt
Rear final drive oil
1.75 3 3/4 pt 3 1/8 pt
Transfer fluid
3.0 3 1/8 qt 2 5/8 qt
Front final drive oil
1.6 3 3/8 pt 2 7/8 pt
Power steering fluid (PSF)
1.0 2 1/8 pt 1 3/4 pt
Windshield washer fluid
4.5 1 1/4 gal 1 gal
Air conditioning system refrigerant 1.08 ± 0.05 kg 2.38 ± 0.11 lb 2.38 ± 0.11 lb
Air conditioning system lubricants
290 m9.8 fl oz 10.2 fl oz

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BR
A
B
BR
Revision: October 20052005 QX56 PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 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
INSPECTION ........................................................ 6
ADJUSTMENT ...................................................... 6
Removal and Installation .......................................... 7
REMOVAL ............................................................. 8
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 PIPING AND HOSE .....................................11
Hydraulic Circuit ......................................................11
Removal and Installation of Front Brake Hose ........11
REMOVAL ............................................................11
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Hose ....... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-board Inspection ............................................... 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14INSTALLATION ................................................... 15
Disassembly and Assembly .................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 15
BRAKE BOOSTER ................................................... 16
On-Vehicle Service ................................................. 16
OPERATING CHECK .......................................... 16
AIRTIGHT CHECK .............................................. 16
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
VACUUM LINES ....................................................... 19
Removal and Installation ........................................ 19
Inspection ............................................................... 19
VISUAL INSPECTION ......................................... 19
CHECK VALVE INSPECTION ............................. 19
FRONT DISC BRAKE ............................................... 20
On-vehicle Inspection ............................................. 20
PAD WEAR INSPECTION ................................... 20
Components ........................................................... 20
Removal and Installation of Brake Pad .................. 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
Removal and Installation of Brake Caliper Assembly
and Disc Rotor ........................................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 22
DISASSEMBLY ................................................... 22
CALIPER INSPECTION ...................................... 23
ASSEMBLY ......................................................... 23
DISC ROTOR INSPECTION ............................... 24
BRAKE BURNISHING PROCEDURE ................. 24
REAR DISC BRAKE ................................................. 26
On-vehicle Inspection ............................................. 26
PAD WEAR INSPECTION ................................... 26
Components ........................................................... 26
Removal and Installation of Brake Pad .................. 27
REMOVAL ........................................................... 27

BR-2Revision: October 20052005 QX56 INSTALLATION .................................................... 27
Removal and Installation of Brake Caliper and Disc
Rotor ....................................................................... 27
REMOVAL ........................................................... 27
INSTALLATION .................................................... 27
Disassembly and Assembly of Brake Caliper ......... 28
DISASSEMBLY ................................................... 28
CALIPER INSPECTION ...................................... 28
ASSEMBLY ......................................................... 29
DISC ROTOR INSPECTION ............................... 29
BRAKE BURNISHING PROCEDURE ................. 30SERVICE DATA AND SPECIFICATIONS (SDS) ......31
General Specifications ............................................31
Brake Pedal ............................................................31
Brake Booster .........................................................31
Check Valve ............................................................31
Front Disc Brake .....................................................31
Rear Disc Brake ......................................................32

PRECAUTIONS
BR-3
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: October 20052005 QX56
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS004VW
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.
WA RN ING:

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 Brake SystemEFS004VX

Always use recommended brake fluid. Refer to MA-11, "RECOMMENDED 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 clean brake fluid.

Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.

Use flare nut wrench when removing and installing brake tube.

Always check tightening torque when installing brake lines.

Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery
terminals.

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" .
WA RN ING:

Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.SBR6 86 C

FRONT DISC BRAKE
BR-21
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: October 20052005 QX56
WA RN ING:
Clean dust on cylinder body and brake pads 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.

It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch
brake hose.

Do not damage piston boot.

Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft
pedal occurs at very low mileage. Refer to BR-24, "
BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake PadEFS004WI
REMOVAL
1. Remove tires from vehicle using power tool.
2. Remove lower sliding pin bolt.
3. Suspend cylinder body with a wire and remove pad retainers, pads, and shims from torque member.
INSTALLATION
1. Push pistons in so that pad is firmly installed and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
2. Attach pad retainers, pads, and shims to torque member.
NOTE:
Apply Molykote M-77 grease to shims and pad retainers where brake pads contact.
CAUTION:
When attaching pad retainer, attach it firmly so that it does
not float up higher than torque member, as shown in the fig-
ure.
3. Install lower sliding pin bolt and tighten it to the specified torque.
Refer to BR-20, "
Components" .
4. Check brake for drag.
5. Install tires to the vehicle. Refer to WT-7, "
Rotation" .
Removal and Installation of Brake Caliper Assembly and Disc RotorEFS004WJ
REMOVAL
1. Remove tires from vehicle using power tool.
2. Drain brake fluid as necessary. Refer to BR-9, "
Drain and Refill" .
NOTE:
Do not remove union bolt unless removing cylinder body from vehicle.
3. Remove torque member bolts.
NOTE:
Position cylinder body aside using suitable wire, as necessary.
NOTE:
When servicing cylinder body, remove sliding pin bolts and torque member from cylinder body.
4. Remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .
PFIA0273E

BR-22
FRONT DISC BRAKE
Revision: October 20052005 QX56

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install sliding pin bolts and torque member to caliper, if removed. Refer to BR-20, "
Components" .
3. Install caliper assembly to the vehicle, then tighten the torque
member bolts to the specified torque. Refer to BR-20, "
Compo-
nents" .
CAUTION:

When attaching caliper assembly to the vehicle, wipe any
oil off knuckle spindle, washers and caliper assembly
attachment surfaces.

Do not reuse caliper torque member bolts.
4. Install brake hose to cylinder body, then tighten union bolt to the
specified torque as necessary. Refer to BR-20, "
Components" .
CAUTION:

Do not reuse copper washer.

Attach brake hose to caliper assembly together with
union bolt and washers.
5. Refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
6. Attach tires to the vehicle. Refer to WT-7, "
Rotation" .
Disassembly and Assembly of Brake Caliper AssemblyEFS004WK
DISASSEMBLY
1. Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque
member.
2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown, and blow air from union bolt
mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
LFIA0209E
LFIA0214E
MAA0272D

BR-24
FRONT DISC BRAKE
Revision: October 20052005 QX56
2. Apply brake fluid to piston and piston boot, then install piston
boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder body inner wall from being
rubbed.
4. Install sliding pins and sliding pin boots to torque member.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
5. Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to BR-20, "
Components" .
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 wheel hub at 2 or more positions.
2. Inspect runout using a dial gauge. (Measured at 10mm (0.39 in)
inside the disc edge.)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-5, "
WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole.
4. If runout still out of specification, turn rotor with on-car brake
lathe.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
WFIA0211E
Runout limit (on vehicle) : 0.04 mm (0.0016 in)
BRA0013D
Standard thickness : 26.0 mm (1.024 in)
Repair limit thickness : 24.5 mm (0.965 in)
Maximum uneven wear
(Measured at 8 positions): 0.015 mm (0.0006 in)
SBR0 20 B

REAR DISC BRAKE
BR-27
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: October 20052005 QX56
CAUTION:

While removing cylinder body, never 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 cylinder body. In this case, hang cylinder body with a wire so as not to stretch
brake hose.

Do not damage piston boot.

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-30, "
BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake PadEFS004WN
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove mounting bolt from the top mount.
3. Swing cylinder body open, and remove pads.
INSTALLATION
1. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
2. Install pads to cylinder body.
3. Install top mounting bolt and tighten to specification.
4. Check brake for drag.
5. Install tires to the vehicle. Refer to WT-7, "
Rotation" .
Removal and Installation of Brake Caliper and Disc RotorEF S0 04 WO
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid as necessary. Refer to BR-9, "
Drain and Refill" .
NOTE:
Do not remove union bolt unless removing cylinder body from vehicle.
3. Remove mounting bolts and cylinder body.
NOTE:
Position cylinder body aside using suitable wire, as necessary.
4. Remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid. Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" .

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install cylinder body to the vehicle, and tighten mounting bolts to specification. Refer to BR-26, "
Compo-
nents" .
CAUTION:
Before installing cylinder body to the vehicle, wipe off mounting surface of cylinder body.
3. Install brake hose to cylinder body and tighten union bolt to specification as necessary. Refer to BR-26,
"Components" .
LFIA0211E

REAR DISC BRAKE
BR-29
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: October 20052005 QX56
ASSEMBLY
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply clean brake fluid to new piston seal and insert in to
groove on cylinder body. Refer to MA-11, "
RECOMMENDED
FLUIDS AND LUBRICANTS" .
CAUTION:
Do not reuse piston seal.
2. Apply brake fluid to piston and to piston boot, then install piston
boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder body inner wall from being
rubbed.
4. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection
1. Using wheel nuts, install disc rotor to wheel hub. (2 or more positions.)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside disk edge.]
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cation before measuring runout. Refer to RAX-5, "
WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole.
4. If runout still out of specification, turn rotor with on-car brake
lathe.
WFIA0210E
WFIA0211E
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
BRA0013D