front brake caliper INFINITI QX56 2006 Factory Service Manual

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION
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BR
Revision: November 2009 2006 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
INSTALLATION ................................................ ... 18
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 ................................................ ... 22
Disassembly and Assembly of Brake Caliper ...... ... 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
REMOVAL ........................................................ ... 28
INSTALLATION ................................................ ... 28

BR-2Revision: November 20092006 QX56
Removal and Installation of Brake Caliper and Disc
Rotor ....................................................................
... 28
REMOVAL ........................................................ ... 28
INSTALLATION ................................................. ... 28
Disassembly and Assembly of Brake Caliper ...... ... 29
DISASSEMBLY ................................................ ... 29
CALIPER INSPECTION ................................... ... 29
ASSEMBLY ...................................................... ... 30
DISC ROTOR INSPECTION ............................ ... 30
BRAKE BURNISHING PROCEDURE .............. ... 31SERVICE DATA AND SPECIFICATIONS (SDS) ...
... 32
General Specifications ......................................... ... 32
Brake Pedal ......................................................... ... 32
Brake Booster ...................................................... ... 32
Check Valve ......................................................... ... 32
Front Disc Brake .................................................. ... 32
Rear Disc Brake ................................................... ... 33

PRECAUTIONSBR-3
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BR
Revision: November 2009 2006 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.
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 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-25, "
BRAKE BURNISHING PROCEDURE" .
WARNING:

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

BR-22
FRONT DISC BRAKE
Revision: November 20092006 QX56
WARNING:
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-25, "
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 pads, shims and pad retainers from torque member.
INSTALLATION
1. Push pistons in so that pad is firmly installed and mount cylinder body to torque member.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in piston.
2. Attach pad retainers, pads and shims to torque member.

Apply Molykote M-77 grease to pad retainer where brake pad
contacts and between pad and shim.
CAUTION:

When attaching pad retainer, attach it firmly so that it is
seated fully in the torque member as shown.

Do not get grease on the brake rotor friction surface.
3. Install lower sliding pin bolt and tighten it to the specified torque. Refer to BR-21, "
Components" .
4. Check brake for drag.
5. Install tires to the vehicle. Refer to WT-7, "
Rotation" .
Removal and Installation of Brake Caliper and Disc RotorEFS004WJ
REMOVAL
1. Remove tires from vehicle using power tool.
2. Drain brake fluid as necessary. Refer to BR-10, "
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

FRONT DISC BRAKEBR-23
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BR
Revision: November 2009 2006 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-21, "
Components" .
3. Install caliper assembly to the vehicle, then tighten the torque member bolts to the specified torque. Refer to BR-21, "
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 specification, as necessary. Refer to BR-21, "
Components" .
CAUTION:

Do not reuse copper washer.

Install brake hose to caliper assembly together with
union bolt and washers.
5. Refill with new brake fluid and bleed air. Refer to BR-11, "
Bleeding Brake System" .
6. Install tires to the vehicle. Refer to WT-7, "
Rotation" .
Disassembly and Assembly of Brake CaliperEFS004WK
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: November 20092006 QX56
4. Using a suitable tool, remove piston seal from cylinder body as
shown.
CAUTION:
Be careful not to damage cylinder body inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene. Refer to
MA-11, "
RECOMMENDED FLUIDS AND LUBRICANTS" .

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.
To r q u e M e m b e r
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
ditions are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
Sliding Pins, and Sliding Pin Boots
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
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 seal in to
groove on cylinder body.
CAUTION:
Do not reuse piston seal.
SFIA1301E
WFIA0210E

PRECAUTIONSBRC-3
[VDC/TCS/ABS]
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M A
B
BRC
Revision: November 2009 2006 QX56
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS0068A
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 Brake System EFS004X4
CAUTION:

Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS" for recommended brake fluid.

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.

To clean or wash all parts of master cylinder and disc brake caliper, use clean brake fluid.

Never 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.

If a brake fluid leak is found, the part must be disassembled
without fail. Then it has to be replaced with a new one if a
defect exists.

Turn the ignition switch OFF and remove the connector of
the ABS actuator and electric unit (control unit) or the bat-
tery terminal before performing the work.

Always torque brake lines when installing.

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-25, "
BRAKE BURNISHING PROCEDURE" (front disc brake) or BR-31, "BRAKE BUR-
NISHING PROCEDURE" (rear disc brake).
WARNING:

Clean brake pads and shoes with a waste cloth, then wipe with a dust collector.
Precautions When Using CONSULT-IIEFS004X5
When connecting CONSULT-II to data link connector, connect them through CONSULT-II CONVERTER.
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carries out CAN communication.
CHECK POINTS FOR USING CONSULT-II
1. Has CONSULT-II been used without connecting CONSULT-II CONVERTER on this vehicle?

If YES, GO TO 2.
SBR686C

BRC-64
[VDC/TCS/ABS]
WHEEL SENSORS
Revision: November 20092006 QX56
WHEEL SENSORSPFP:47910
Removal and InstallationEFS0068D
REMOVAL
1. Remove wheel sensor bolt.

When removing the front wheel sensor, first remove the disc rotor to gain access to the front wheel sen-
sor bolt. Refer to BR-22, "
Removal and Installation of Brake Caliper and Disc Rotor" .

When removing the rear wheel sensor, first remove the rear hub and bearing assembly to gain access
to the rear wheel sensor bolt. Refer to RAX-5, "
Removal and Installation" .
2. Pull out the sensor, being careful to turn it as little as possible. CAUTION:

Do not pull on the sensor harness.
3. Disconnect wheel sensor harness electrical connector, then remove harness from attaching points.
INSTALLATION
Installation is in the reverse order of removal. Tighten wheel sensor bolt to specification.
CAUTION:
Installation should be performed while paying attention to the following.

Inspect wheel sensor O-ring, replace sensor assembly if damaged.

Before installing wheel sensor, make sure no foreign materials (such as iron fragments) are
adhered to the pick-up part of the sensor, to the inside of the sensor hole or on the rotor mating
surface.

Apply a coat of suitable grease to the wheel sensor O-ring and hole. Refer to MA-11, "RECOM-
MENDED FLUIDS AND LUBRICANTS" .
WFIA0376E

WHEEL HUBFAX-5
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Revision: November 2009 2006 QX56
WHEEL HUBPFP:43202
On-Vehicle Inspection and ServiceEDS003BN
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are normal.
WHEEL BEARING INSPECTION

Move wheel hub in the axial direction by hand. Make sure there
is no looseness of wheel bearing.

Rotate wheel hub and make sure there is no unusual noise or
other irregular conditions. If there are any irregular conditions,
replace wheel hub and bearing assembly.
Removal and InstallationEDS003BO
REMOVAL
1. Remove wheel and tire using power tool.
2. Remove engine under cover using power tool.
3. Without disassembling the hydraulic lines, remove caliper torque member bolts using power tool. Then
reposition brake caliper aside with wire. Refer to BR-22, "
Removal and Installation of Brake Caliper and
Disc Rotor" .
NOTE:
Do not press brake pedal while brake caliper is removed. Axial end play limit : 0.05 mm (0.002 in) or less
SMA571A
1. Disc rotor
2. Wheel hub and bearing assembly 3. Wheel stud
4. Splash guard 5. Steering knuckle⇐Front
WDIA0328E

DRIVE SHAFTFAX-7
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Revision: November 2009 2006 QX56
DRIVE SHAFTPFP:39100
Removal and InstallationEDS003BP
REMOVAL
1. Remove wheel and tire using power tool.
2. Remove engine under cover using power tool.
3. Remove wheel sensor harness from mount on knuckle.
CAUTION:
Do not pull on wheel sensor harness.
4. Without disassembling the hydraulic lines, remove brake caliper using power tool. Reposition it aside with wire. Refer to BR-22, "
Removal and Installation of Brake Caliper and Disc Rotor" .
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
5. Remove coil spring and shock absorber assembly using power tool. Refer to FSU-10, "
Removal and
Installation" .
6. Separate upper link ball joint stud from steering knuckle using To o l .

Support lower link with jack.
7. Remove cotter pin, then remove drive shaft nut.
8. Remove drive shaft mounting bolts from front final drive.
9. Remove drive shaft from wheel hub and bearing assembly. CAUTION:

When removing drive shaft, do not apply an excessive
angle to drive shaft joint. Also be careful not to exces-
sively extend slide joint.
INSPECTION AFTER REMOVAL

Move joint up, down, left, right, and in axial direction. Check for any rough movement or significant loose-
ness.

Check boot for cracks or other damage, and for grease leakage.

If damaged, disassemble drive shaft to verify damage, and
repair or replace as necessary.
1. Cotter pin 2. Drive shaft nut3. Drive shaft
WDIA0329E
Tool number : ST29020001 (J-24319-01)
LEIA0095E
RAA0030D