2004 INFINITI FX35 brake system

BL-110
INTELLIGENT KEY SYSTEM
Revision: 2004 November 2004 FX35/FX45
26 P/L Stop lamp switch —Brake pedal depressed (ON) 5
Brake pedal not depressed (OFF) 0
27 L/W Ignition knob switch —Press ignition knob. 12
Return ignition knob to LOCK position. 0
28 W/B Door unlock sensor — Door is locking → unlock 5 → 0
29 GYDoor request switch
(back door)—Back door request switch operation:
Press (ON)0
Other than the above (OFF) 5
31 Y/B Steering lock unit ground — — 0
32 R/BSteering lock unit com-
municationLOCKPress ignition knob with Intelligent Key
inside vehicle.
Other than the above 5
35 LGInside key antenna (+)
signal
(Dashboard)
LOCKAny door open → Close (Door switch:
ON → OFF)
Ignition knob switch: ON (press ignition
knob.)
36 PUInside key antenna (-)
signal
(Dashboard)
37 G Outside antenna RH (+)
LOCKPassenger door request switch opera-
tion (Switch: ON)
38PU/
WOutside antenna RH (-)
39 R/Y Detention switch LOCKA/T selector lever in “P” position. 0
A/T selector lever in other position. Battery voltage
40BR/
WDoor lock relay LOCKDoor request switch (passenger side)
pressedBattery voltage → 0 → Battery
voltage Te r -
minal
No.Wire
colorItemMeasuring condition
Standard (V)
Approx. Ignition knob
positionOperation or conditions
SIIA1911J
SIIA1910J
SIIA1910J

BL-116
INTELLIGENT KEY SYSTEM
Revision: 2004 November 2004 FX35/FX45
ACTIVE TEST
ACC SW [ON/OFF]Displays status (Ignition switch ACC position: ON/Ignition switch OFF position:
OFF) as judged from ignition switch signal.
DOOR STAT SW [ON/OFF] Displays status from door unlock sensor ON/OFF condition.
STOP LAMP SW [ON/OFF]Displays status (Brake pedal depress: ON/brake pedal not depress: OFF) as
judged from stop lamp switch signal.
P RANGE SW [ON/OFF] Displays status from park/neutral position switch ON/OFF condition.
BD OPEN SW [ON/OFF]Displays status (Back door open: ON/Back door closed: OFF) as judged from back
door opener switch signal.
CAN COMM [ON/OFF] Display CAN communication system.
CAN CIRC 1 [ON/OFF] Display CAN communication system.
CAN CIRC 2 [ON/OFF] Display CAN communication system.
CAN CIRC 3 [ON/OFF] Display CAN communication system.
CAN CIRC 4 [ON/OFF] Display CAN communication system.Monitor item [OPERATION] Description
Monitor item Description
DOOR LOCK/UNLOCKThis test is able to check all door lock actuators lock/unlock operation. These
actuators lock when “ON” on CONSULT-II screen is touched.
OUTSIDE BUZZERThis test is able to check Intelligent Key warning buzzer operation. The buzzer will
be activated on when “ON” on CONSULT-II screen is touched.
INSIDE BUZZERThis test is able to check buzzer (bultin combination meter) operation. The buzzer
will be activated on when “ON” on CONSULT-II screen is touched.
INDICATORThis test is able to check warning lamp operation. The lamp will be turned on
when “ON” on CONSULT-II screen is touched.

INTELLIGENT KEY SYSTEM
BL-141
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Revision: 2004 November 2004 FX35/FX45
4. STEERING LOCK UNIT COMMUNICATION CIRCUIT INSPECTION
1. Disconnect Intelligent Key unit and steering lock unit connectors.
2. Check continuity between Intelligent Key unit connector M34 terminals 1, 31, 32 and steering lock unit
connector M26 terminals 2, 3, 4.
3. Check continuity between steering lock unit connector M26 ter-
minals 2, 3, 4 and ground.
OK or NG
OK >> Replace steering lock unit.

After replacing steering lock unit, perform registration procedure. Refer to “CONSULT-II Opera-
tion Manual NATS-IVIS/NVIS”.
NG >> Repair or replace harness between steering lock unit and Intelligent Key unit.
Check Stop Lamp SwitchAIS004NM
1. STOP LAMP SWITCH POWER SUPPLY CIRCUIT INSPECTION
1. Disconnect stop lamp switch connector.
2. Check voltage between stop lamp switch connector E210 termi-
nal 1 (GY) and ground.
OK or NG
OK >> GO TO 2.
NG >> Repair or replace harness between stop lamp switch
and fuse.
2. STOP LAMP SWITCH OPERATION INSPECTION
Check continuity between stop lamp switch connector E210 terminal
1 and 2.
OK or NG
OK >> GO TO 3.
NG >> Replace stop lamp switch.1 (R/W) - 2 (R/W) : Continuity should exist.
31 (Y/B) - 4 (Y/B) : Continuity should exist.
32 (R/B) - 3 (R/B) : Continuity should exist.
2 (R/W) - Ground : Continuity should not exist.
3 (R/B) - Ground : Continuity should not exist.
4 (Y/B) - Ground : Continuity should not exist.
PIIA6799E
1 (GY) - Ground : Battery voltage
PIIA6811E
1 - 2
Brake pedal depressed : Continuity should exist.
Brake pedal not
depressed: Continuity should not exist.
PIIA6800E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
A
B
BR
Revision: 2004 November 2004 FX35/FX45
BRAKE SYSTEM
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
PLAY AND CLEARANCE BETWEEN BRAKE
PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED ........................................................ 6
ADJUSTMENT ...................................................... 7
Removal and Installation .......................................... 7
COMPONENT PARTS LOCATION ....................... 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 Piping and
Brake Hose ............................................................. 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Removal and Installation of Rear Brake Piping and
Brake Hose ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 12
BRAKE MASTER CYLINDER .................................. 13
On-board Inspection ............................................... 13
LEAK INSPECTION ............................................ 13Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Components ........................................................... 13
Disassembly and Assembly .................................... 14
DISASSEMBLY ................................................... 14
ASSEMBLY ......................................................... 14
BRAKE BOOSTER ................................................... 15
On-Vehicle Service ................................................. 15
OPERATING CHECK .......................................... 15
AIRTIGHT CHECK .............................................. 15
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 16
INSTALLATION ................................................... 17
VACUUM LINES ....................................................... 18
Removal and Installation ........................................ 18
Inspection ............................................................... 18
VISUAL INSPECTION ......................................... 18
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
... 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 ................................................. 25
On-vehicle Inspection ............................................. 25

PRECAUTIONS
BR-3
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Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AFS0028A
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 SystemAFS001MQ

Recommended fluid is brake fluid “DOT 3”.

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.

When installing brake piping, be sure to check torque.

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

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" .
WARNING:

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

BRAKE FLUID
BR-9
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Revision: 2004 November 2004 FX35/FX45
BRAKE FLUIDPFP:KN100
On-board InspectionAFS001MV
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 RefillAFS001MW
CAUTION:

Refill with new brake fluid “DOT3”.

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. Refer to BR-10, "
Bleeding Brake System" .
SFIA1032E
BRA0007D
SBR995

BR-10
BRAKE FLUID
Revision: 2004 November 2004 FX35/FX45
Bleeding Brake SystemAFS001MX
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 terminal.
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, 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-20, "
Components" (front disc brake), BR-25,
"Components" (rear disc brake).
7. In steps 2 to 6 below, with master cylinder reservoir tank filled at least half way, bleed air from the front left,
rear left, and front right bleed valve, in that order.

BRAKE PIPING AND HOSE
BR-11
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Revision: 2004 November 2004 FX35/FX45
BRAKE PIPING AND HOSEPFP:46210
Hydraulic CircuitAFS001MY
CAUTION:

All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.

Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.

The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
the parts. Replace applicable part with a new one, if necessary.

Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.

Do not bend or twist brake hose sharply, or strongly pull it.

When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.

Refill with new brake fluid “ DOT 3 ”

Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose AFS001MZ
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from caliper assembly.
4. Remove lock plate and remove brake hose from the vehicle.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt to the specified torque.
NOTE:
Do not reuse copper washer.
2. Install brake hose to brake tube, partially tighten flare nut as far
as possible by hand, then secure it to bracket with lock plate.
3. Using a flare nut wrench, tighten flare nut to the specified
torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
SFIA1941E
SFIA1204E