air bleeding INFINITI QX56 2004 Factory Service Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BR
A
B
BR
Revision: August 20072004 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
Special Service Tool ................................................. 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 ...................................................... 7
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 9
INSTALLATION ..................................................... 9
BRAKE FLUID .......................................................... 10
On-board Inspection ............................................... 10
LEVEL CHECK ................................................... 10
Drain and Refill ....................................................... 10
Bleeding Brake System ...........................................11
BRAKE PIPING AND HOSE .................................... 12
Hydraulic Circuit ..................................................... 12
Removal and Installation of Front Brake Hose ....... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
Removal and Installation of Rear Brake Hose ....... 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Inspection After Installation .................................... 14
BRAKE MASTER CYLINDER .................................. 15
On-board Inspection ............................................... 15
LEAK INSPECTION ............................................ 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15INSTALLATION ................................................... 16
Disassembly and Assembly .................................... 16
DISASSEMBLY ................................................... 16
ASSEMBLY ......................................................... 16
BRAKE BOOSTER ................................................... 17
On-Vehicle Service ................................................. 17
OPERATING CHECK .......................................... 17
AIRTIGHT CHECK .............................................. 17
Removal and Installation ........................................ 18
REMOVAL ........................................................... 18
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 19
VACUUM LINES ....................................................... 20
Removal and Installation ........................................ 20
Inspection ............................................................... 20
VISUAL INSPECTION ......................................... 20
CHECK VALVE INSPECTION ............................. 20
FRONT DISC BRAKE ............................................... 21
On-vehicle Inspection ............................................. 21
PAD WEAR INSPECTION ................................... 21
Components ........................................................... 21
Removal and Installation of Brake Pad .................. 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 22
Removal and Installation of Brake Caliper and Disc
Rotor ....................................................................... 22
REMOVAL ........................................................... 22
INSTALLATION ................................................... 23
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 23
DISASSEMBLY ................................................... 23
CALIPER INSPECTION ...................................... 24
ASSEMBLY ......................................................... 24
DISC ROTOR INSPECTION ............................... 25
BRAKE BURNISHING PROCEDURE ................. 25
REAR DISC BRAKE ................................................. 27
On-vehicle Inspection ............................................. 27
PAD WEAR INSPECTION ................................... 27
Components ........................................................... 27
Removal and Installation of Brake Pad .................. 28

BR-10
BRAKE FLUID
Revision: August 20072004 QX56
BRAKE FLUIDPFP:KN100
On-board InspectionEFS003P9
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 leaks.

If fluid level is excessively low, check brake system for leaks.

If brake warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.
Drain and RefillEFS003PA
CAUTION:

Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .

Do not reuse drained brake fluid.

Do not let brake fluid splash on the painted surfaces of the body. This might damage the paint, so
when splashing it, immediately wipe off the area and wash away with water.

Before servicing, disconnect actuator connector or battery negative cable.
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 bleed 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.
Bleed air from brake system. Refer to BR-11, "
Bleeding Brake
System" .
LFIA0225E
SBR4 19 C
SBR9 95

BRAKE FLUID
BR-11
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: August 20072004 QX56
Bleeding Brake SystemEFS003PB
CAUTION:
While bleeding, pay attention to master cylinder fluid level.
1. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector or battery
negative cable.
2. Connect a vinyl tube to the rear right bleed valve.
3. Fully depress brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen bleed valve to let the air out, and then tighten it immediately.
5. Repeat steps 3 and 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-21, "
Components" (front disc brake), BR-27,
"Components" (rear disc brake).
7. Repeat steps 2 through 6, with master cylinder reservoir tank filled at least half way, bleed air from the
front left, rear left, and front right bleed valve.

BRAKE PIPING AND HOSE
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: August 20072004 QX56
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt.
CAUTION:
Do not reuse copper washer.
2. Insert brake hose end through bracket, then secure it to bracket
with lock plate.
3. Install brake tube to brake hose, then tighten flare nut using a
flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake
System" .
Removal and Installation of Rear Brake Hose EFS003PE
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt.
CAUTION:
Do not reuse copper washers.
2. Insert brake hose end through bracket, then secure it to bracket
with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to using a
flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake
System" .
LFIA0214E
LFIA0213E
LFIA0212E
LFIA0213E

BR-16
BRAKE MASTER CYLINDER
Revision: August 20072004 QX56
INSTALLATION

Installation is in the reverse order of removal.

Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
CAUTION:

Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .

Do not reuse drained brake fluid.

Adjust brake pedal. Refer to BR-7, "ADJUSTMENT" .
Disassembly and AssemblyEFS003PI
DISASSEMBLY
CAUTION:

Master cylinder cannot be disassembled.

Remove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY
CAUTION:

Never use mineral oil 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 or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer
to GI-45, "
RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
CAUTION:
Do not reuse grommet.
2. Install reservoir tank onto master cylinder sub-assembly.

BRAKE BOOSTER
BR-19
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: August 20072004 QX56
INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length B (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut and install
booster assembly to the vehicle.

Install a gaskets and spacer block between booster assembly
and the dash panel.
3. Connect brake pedal with clevis of input rod.
4. Install pedal bracket mounting nuts and tighten them to the
specified torque.
5. Install brake piping from brake master cylinder to ABS actuator. Refer to BR-12, "
Hydraulic Circuit" .
6. Connect active boost and delta stroke sensor harness connectors to brake booster assembly.
7. Connect vacuum hose to brake booster.
8. Install master cylinder to booster assembly. Refer to BR-18, "
Removal and Installation" .
9. Adjust the height and play of brake pedal.
10. Tighten lock nut of input rod to the specified torque.
11. Install engine air duct assembly. Refer to EM-14, "
Removal and Installation" .
12. Install engine room cover with power tool. Refer to EM-11, "
Removal and Installation" .
13. Refill with new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" . Length “B” : 125 mm (4.92 in)
SGIA0060E

FRONT DISC BRAKE
BR-23
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: August 20072004 QX56
INSTALLATION
CAUTION:

Refill with new brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" .

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install torque member and tighten to specification. Refer to BR-21, "
Components" .
3. Install sliding pin bolts, if removed.
4. Install cylinder body, then tighten sliding pin bolts to the specified
torque. Refer to BR-21, "
Components" .
CAUTION:

When attaching cylinder body to the vehicle, wipe any oil
off knuckle spindle, washers and cylinder body attach-
ment surfaces.

Do not reuse cylinder body torque member bolts.
5. Install brake hose to cylinder body, if removed, then tighten
union bolt to the specified torque. Refer to BR-21, "
Compo-
nents" .
CAUTION:

Do not reuse copper washers for union bolt.

Attach brake hose to cylinder body together with union
bolt and washers.
6. Refill new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
7. Install wheel and tire. Refer to WT-6, "
Rotation" .
Disassembly and Assembly of Brake Caliper AssemblyEFS003PR
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 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.
LFIA0209E
LFIA0214E
MAA0272D

REAR DISC BRAKE
BR-29
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: August 20072004 QX56
3. Install brake hose to cylinder body and tighten union bolt to specification as necessary. Refer to BR-27,
"Components" .
CAUTION:

Do not reuse copper washers.

Securely attach brake hose to protrusion on cylinder body.
4. Refill with new brake fluid and bleed air as necessary. Refer to BR-11, "
Bleeding Brake System" .
5. Install tires to the vehicle. Refer to WT-6, "
Rotation"
Disassembly and Assembly of Brake Caliper AssemblyEFS003PW
DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body body.
3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Do not get your fingers caught in piston.
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION:
Be careful not to damage cylinder body inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

Check inside surface of cylinder body for score, rust wear, damage or foreign materials. If any of
the above conditions are observed, replace cylinder body.

Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:

Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials
are stuck to sliding surface.

Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above conditions are observed.
Sliding Pin Bolts and Sliding Pin Boots
Make sure there is no wear, damage, or cracks in sliding sleeve and sliding sleeve boots, and if there are,
replace them.
BRD0041D
PFIA0269E

ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
BRC-67
[VDC/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Revision: August 20072004 QX56
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
To install, use a flare nut wrench (commercial service tool).

Always tighten brake tubes to specification when installing. Refer to BR-12, "BRAKE PIPING AND
HOSE" .

Never reuse drained brake fluid.

After installation of the ABS actuator and electric unit (control unit), refill brake system with new
brake fluid. Then bleed the air from the system. Refer to BR-11, "
Bleeding Brake System" .

After installation of ABS actuator, adjust steering angle sensor. Refer to BRC-62, "Adjustment of
Steering Angle Sensor Neutral Position" .

After installation of ABS actuator, calibrate the decel G sensor. Refer to BRC-62, "Calibration of
Decel G Sensor" .

CO-16Revision: August 2007
WATER PUMP
2004 QX56

For bleeding the air from the cooling system, refer to MA-13, "REFILLING ENGINE COOLANT" .
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant. Refer to CO-8, "CHECKING COOLING SYSTEM FOR LEAKS" .

Start and warm up engine. Visually make sure that there are no leaks of engine coolant.