INFINITI QX56 2011 Factory Service Manual

HYDRAULIC BOOSTER ASSEMBLYBR-31
< REMOVAL AND INSTALLATION >
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2. Remove the reservoir tank mounting pin with a pin punch (com- mercial service tool).
3. Remove bolt and remove the reservoir tank and grommets from the ABS actuator and electric unit (control unit).
CAUTION:
Never drop the removed parts. The parts must not be
reused if they are dropped.
4. Slide the clamp and remove brake hose assembly.
5. Remove the brake tube with a flare nut wrench. CAUTION:
Never scratch the flare nut and the brake tube.
6. Remove the cap with a suitable tool (A).
7. Remove grommets and screws ( ) and remove motor/accumu- lator assembly harness.
8. Cut harness band. CAUTION:
Never damage the harness.
9. Remove motor/accumulator assembly from ABS actuator and electric unit (control unit).
10. Remove bushings and collars from motor/accumulator assem- bly.
11. Remove brackets and bushing fr om ABS actuator and electric
unit (control unit).
12. Remove pin mount.
13. After replacing motor/accumulator assembly, always follow the accumulator disposal procedure to discard the motor/accumulator assembly. Refer to BR-33, "
Disposal".
ASSEMBLY
Note the following, and assembly in the reverse order of disassembly.
 Never use mineral oils such as kerosene or gasoline and rubber grease during the cleaning and assembly
process.
 Never drop the removed parts when installing. The parts must not be reused if they are dropped.
 Never allow foreign matter (e.g. dust) and oils ot her than brake fluid to enter the reservoir tank.
 For non reusable parts, refer to BR-28, "
Exploded View".
 When connecting motor/accumulator assembly harness, check the order of harness colors.
 Temporarily tighten the brake tube flare nut to the motor/accumula- tor assembly and ABS actuator and electric unit (control unit) by
hand. Then tighten it to the specified torque with a crowfoot and
torque wrench.
CAUTION:
Never scratch the flare nut and the brake tube.
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A: Black
B: Red
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Revision: 2010 May2011 QX56

BR-32
< REMOVAL AND INSTALLATION >
HYDRAULIC BOOSTER ASSEMBLY
 Apply new brake fluid to grommet of between reservoir tank and grommet and ABS actuator and electric unit
(control unit).
Inspection and AdjustmentINFOID:0000000006222486
ADJUSTMENT BEFORE INSTALLATION
Input Rod Length adjustment
1. Loosen the lock nut (1) and adjust the input rod (2) to the speci-
fied length (A).
2. Tighten the lock nut to the specified torque.
INSPECTION AFTER INSTALLATION
Operation Check
1. Turn the ignition switch OFF.
2. Depress the brake pedal 20 times or more. NOTE:
The pressure loss in the accumulator results in a large brake pedal stroke. In addition to this, the brake
pedal depression becomes lighter in initial stage.
3. Check that the fluid level in the reservoir tank is MAX line.
4. Position the selector lever in P range to release the parking brake.
5. Turn the ignition switch ON to check the time between motor activation and motor stop.
6. After the motor is stopped, check that the ABS warn ing lamp and the VDC warning lamp in the combina-
tion meter are OFF when the engine is started.
7. Stop the engine (ignition switch OFF).
8. Turn the ignition switch ON and depress the brake pedal 4 to 5 times to check the time between motor activation and motor stop.
9. Turn the ignition switch OFF. Turn the ignition swit ch ON again. Check that the VDC warning lamp turns
ON when the brake pedal is depressed 15 to 20 times.
10. Check that the VDC warning lamp turns ON when the brake pedal is depressed 15 to 20 times after the lapse of 120 seconds or more after the ignition switch is turned ON again.
11. Perform the self-diagnosis for “ABS” with CONSULT- III and erase all the stored self-diagnosis results.
Function Check
1. Turn the ignition switch OFF.
2. Depress the brake pedal 20 times or more.
NOTE:
The pressure loss in the accumulator results in a large brake pedal stroke. In addition to this, the brake
pedal depression becomes lighter in initial stage.
3. Turn the ignition switch ON with the brake pedal depr essed to check that the clearance between the brake
pedal and the dash lower panel decreases. A : Refer to
BR-47, "
Brake Booster".
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Motor operating time : 18 seconds or less
Motor operating time : 2 − 11 seconds
Revision: 2010 May2011 QX56

HYDRAULIC BOOSTER ASSEMBLYBR-33
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DisposalINFOID:0000000006222487
1. Remove accumulator (2) from motor/accumulator assembly (1).
2. Fix the accumulator (1) to a vise. CAUTION:
 Always set copper plates or cloth between vise gripswhen fixing the accumulator to a vise.
 Never overtighten the vise.
3. Make a slit in the area (A) with a saw to release filler gas.
CAUTION:
 Wear eye protection (safety glasses).
 Wear gloves.
 A cut in the area must be made perpendicularly.
 Perform the procedure slowly.
 Cover with cloth to avoid sawdust to spatter.
NOTE:
The gas is clear colorl ess, odorless, and harmless.
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A : 50 mm (1.97 in)
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Revision: 2010 May2011 QX56

BR-34
< REMOVAL AND INSTALLATION >
FRONT DISC BRAKE
FRONT DISC BRAKE
BRAKE PAD
BRAKE PAD : Exploded ViewINFOID:0000000006222488
BRAKE PAD : Removal and InstallationINFOID:0000000006222489
REMOVAL
WARNING:
Clean any dust from the brake caliper assembly and brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
 Never depress the brake pedal while removing th e brake pads because the piston may pop out.
 If the brake fluid or grease adheres to the brake calip er assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Remove lower sliding pin bolt.
3. Suspend the cylinder body with suitable wire so that the brake hose will not stretch.
4. Remove the pad return springs (1). Then remove brake pads, shims and shim covers.
CAUTION:
1. Outer shim cover 2. Outer shim 3. Outer pad
4. Torque member 5. Pad retainer 6. Pad return spring
7. Inner pad (with pad wear sensor) 8. Inner shim 9. Inner shim cover
10. Cylinder body
: Apply MOLYKOTE
® AS880N or silicone-based grease.
Refer to GI-4, "
Components" for symbols not described on the above.
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Revision: 2010 May2011 QX56

FRONT DISC BRAKEBR-35
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 Never deform the pad retainer when removing the pad retainers (2) from the torque member (1).
 Never damage the piston boot.
 Never drop the brake pads, shims and shim covers.
 Remember each position of the removed brake pads.
5. Perform inspection after removal. Refer to BR-36, "
BRAKE PAD
: Inspection".
INSTALLATION
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
 Never depress the brake pedal while removing th e brake pads because the piston may pop out.
 If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Install the torque member if the pad retainers has been removed. CAUTION:
 Securely assemble the pad retainers (1) so that it will notbe lifted up from the torque member (2).
 Never deform the pad retainers.
2. Apply MOLYKOTE
® AS880N or silicone-based grease mating
faces (A and B) between the brake pad, shim and shim cover,
and install shim and shim cover to the brake pad.
CAUTION:
Always replace the shims and shim covers when replacing
the brake pad.
3. Install the brake pads to the torque member.
4. Install pad return springs (1). CAUTION:
Correctly insert the pad return spring into the pad return
spring hole on the brake pad.
5. Install cylinder body to torque member. CAUTION:
 Never damage the piston boot.
 When replacing brake pad with new one, check a brakefluid level in the reservoir tank because brake fluid
returns to reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool to easily press piston.
6. Install lower sliding bolt and tighter it to the specified torque.
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Revision: 2010 May2011 QX56

BR-36
< REMOVAL AND INSTALLATION >
FRONT DISC BRAKE
7. Depress the brake pedal several times to check that no drag feel is present for the front disc brake. Refer
to BR-36, "
BRAKE PAD : Inspection".
8. Install tires with power tool. Refer to WT-64, "
Exploded View".
BRAKE PAD : InspectionINFOID:0000000006222490
INSPECTION AFTER REMOVAL
 Replace the shims and shim covers if rust is excessively attached.
 Eliminate rust on the pad retainers and the torque mem ber. Replace them if rust is excessively attached.
INSPECTION AFTER INSTALLATION
1. Check a drag of front disc brake. If any drag is found, follow the procedure described below.
2. Remove brake pads. Refer to BR-34, "
BRAKE PAD : Removal and Installation".
3. Press the pistons. Refer to BR-34, "
BRAKE PAD : Removal and Installation".
4. Install brake pads. Refer to BR-34, "
BRAKE PAD : Removal and Installation".
5. Depress the brake pedal several times.
6. Check a drag of front disc brake again. If any drag is found, disassemble the caliper. Refer to BR-38,
"BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing brake pads, or if a soft pedal occurs at very low mileage. Refer to BR-16, "
BRAKE PAD : Inspection and Adjustment".
BRAKE CALIPER ASSEMBLY
BRAKE CALIPER ASSEMBLY : Exploded ViewINFOID:0000000006222491
REMOVAL
DISASSEMBLY
1. Brake caliper assembly
Refer to GI-4, "
Components" for symbols in the figure.
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Revision: 2010 May2011 QX56

FRONT DISC BRAKEBR-37
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BRAKE CALIPER ASSEMBLY : Removal and InstallationINFOID:0000000006222492
REMOVAL
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
 Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
 Never depress the brake pedal. Brake fluid m ay splash while removing the brake hose.
 If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Remove tires with power tool.
2. Fix the disc rotor using wheel nuts.
3. Drain brake fluid. Refer to BR-10, "
Draining".
4. Separate brake hose from brake caliper assembly. Refer to BR-23, "
FRONT : Removal and Installation".
5. Remove torque member mounting bolts, and remove brake caliper assembly. CAUTION:
Never drop brake pad and brake caliper assembly.
6. Remove disc rotor. Refer to FA X - 8 , "
Removal and Installation" (2WD), FAX-18, "Removal and Installation"
(AWD).
INSTALLATION
WARNING:
Clean any dust from the brake caliper assembly an d brake pads with a vacuum dust collector. Never
blow with compressed air.
CAUTION:
 Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it
off immediately and wash with wate r if it gets on a painted surface.
 Never depress the brake pedal. Brake fluid m ay splash while removing the brake hose.
 If the brake fluid or grease adheres to the brake cal iper assembly and disc rotor, quickly wipe it off.
1. Torque member 2. Sliding pin boot 3. Sliding pin
4. Piston boot 5. Piston 6. Piston seal
7. Cylinder body 8. Bleeder valve 9. Cap
: Apply rubber grease.
: Apply brake fluid.
Refer to GI-4, "
Components" for symbols not described on the above.
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Revision: 2010 May2011 QX56

BR-38
< REMOVAL AND INSTALLATION >
FRONT DISC BRAKE
1. Install disc rotor. Refer to FA X - 8 , "Removal and Installation" (2WD), FAX-18, "Removal and Installation"
(AWD).
2. Install the brake caliper assembly to the steeri ng knuckle and tighten the torque member mounting bolts to
the specified torque.
CAUTION:
Never spill or splash any grease and moisture on the torque member mounting face, threads,
mounting bolts. Wipe out any grease and moisture.
3. Install brake hose to brake caliper assembly. Refer to BR-23, "
FRONT : Removal and Installation".
4. Perform the air bleeding. Refer to BR-11, "
Bleeding Brake System".
5. Check a drag of front disc brake. If any drag is found, refer to BR-39, "
BRAKE CALIPER ASSEMBLY :
Inspection".
6. Install tires with power tool. Refer to WT-64, "
Exploded View".
BRAKE CALIPER ASSEMBLY : Disassembly and AssemblyINFOID:0000000006222493
DISASSEMBLY
NOTE:
Never remove the torque member, brake pads and pad retainers when disassembling and assembling the cyl-
inder body.
1. Remove the sliding pin bolt, and remove the cylinder body from the torque member.
CAUTION:
Fix the brake pad at suitable tape so that the brake pad will not drop.
2. Remove sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from brake hose mounting hole to remove pistons and piston boots.
CAUTION:
Never get fingers caught in the pistons.
4. Remove piston seals from cylinder body using suitable tool. CAUTION:
Be careful not to damage a cylinder inner wall.
5. Remove bleeder valve and cap.
6. Perform inspection after disassembly. Refer to BR-39, "
BRAKE
CALIPER ASSEMBLY : Inspection".
ASSEMBLY
1. Install bleeder valve and cap.
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Revision: 2010 May2011 QX56

FRONT DISC BRAKEBR-39
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2. Apply rubber grease to piston seals (1), and install them to cali- per.
CAUTION:
Never reuse piston seals.
3. Apply rubber grease to piston boots (1). Cover the piston (2) end with piston boot, and then install cylinder side lip on piston boots
securely into a groove on cylinder body.
CAUTION:
Never reuse piston boots.
4. Apply new brake fluid to pistons (1). Push piston into cylinder body by hand and push piston boots (2) piston-side lip into the
piston groove.
CAUTION:
Press the pistons evenly and var y the pressing point to pre-
vent cylinder inner wall from being rubbed.
5. Apply rubber grease to sliding pin boots, and install sliding pin boots to torque member.
6. Apply rubber grease to sliding pin, and install the cylinder body.
7. Install sliding pin bolts and tighten it to the specified torque. Refer to BR-34, "
BRAKE PAD : Exploded View".
BRAKE CALIPER ASSEMBLY : InspectionINFOID:0000000006222494
INSPECTION AFTER DISASSEMBLY
Check the following items and replace if necessary.
Cylinder Body
Check the cylinder inner wall for rust, wear, cracks or damage.
CAUTION:
Always clean with new brake fluid. Never clean wit h mineral oil such as gasoline and light oil.
Torque Member
Check the torque member for rust, wear, cracks or damage.
Pistons
Check the surface of the piston for rust, wear, cracks or damage.
CAUTION:
A piston sliding surface is plat ed. Never polish with sandpaper.
Sliding Pin and Sliding Pin Boot
Check the sliding pins and sliding pin boots for rust, wear, cracks or damage.
INSPECTION AFTER INSTALLATION
1. Check a drag of front disc brake. If any dr ag is found, follow the procedure described below.
2. Remove brake pads. Refer to BR-34, "
BRAKE PAD : Removal and Installation".
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Revision: 2010 May2011 QX56

BR-40
< REMOVAL AND INSTALLATION >
FRONT DISC BRAKE
3. Press the pistons. Refer to BR-34, "BRAKE PAD : Removal and Installation".
4. Install brake pads. Refer to BR-34, "
BRAKE PAD : Removal and Installation".
5. Depress the brake pedal several times.
6. Check a drag of front disc brake again. If any drag is found, disassemble the caliper. Refer to BR-38,
"BRAKE CALIPER ASSEMBLY : Disassembly and Assembly".
7. Burnish contact surfaces brake pads and disc rotor after refinishing or replacing disc rotor, or if a soft pedal occurs at very low mileage. Refer to BR-16, "
DISC ROTOR : Inspection and Adjustment".
Revision: 2010 May2011 QX56