2004 INFINITI QX56 Ins

BL-162
BODY REPAIR
Revision: August 20072004 QX56
1. Hoodledge assembly (RH, LH)
2. Hoodledge reinforcement (RH, LH)
3. Body mounting bracket (RH, LH)
4. Hoodledge front brace (RH), Battery mounting bracket (LH)
5. Harness connector bracket
6. Rear floor reinforcement
7. Rear floor
8. Rear floor reinforcement
9. Rear floor side (RH, LH)
10. Crossmember
11. Second seat rear crossmember
12. Second seat front crossmember
13. Rear front seat crossmember
14. Second Body crossmember
15. Front floor
16. Front seat front crossmember
17. Front floor reinforcement
18. Outer sill (RH, LH)
19. Second crossmember extension
20. Rear crossmember end
21. Rear lower crossmember end
22. Rear crossmember end (RH, LH)
23. Rear side member rear reinforcement (RH, LH)
24. Rear side member (RH, LH)
25. Rear side member reinforcement (RH, LH)
26. Inner sill extension (RH, LH)
27. Rear crossmember
28. Upper dash top
29. Upper dash bottom
30. Cowl top
31. Lower dash
32. Lower dash insulator (RH)
33. Lower dash reinforcement
34. Side dash (RH, LH)
35. Lower dash insulator

BL-168
BODY REPAIR
Revision: August 20072004 QX56
ANTI-CORROSIVE WAX
To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sec-
tions. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of
the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf
life.
LIIA0905E

BL-192
BODY REPAIR
Revision: August 20072004 QX56
Precautions in Repairing High Strength SteelEIS002UA
High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
HIGH STRENGTH STEEL (HSS) USED IN NISSAN VEHICLES
SP130 is the most commonly used HSS.
SP150 HSS is used only on parts that require much more strength.
Read the following precautions when repairing HSS:
1. Additional points to consider

The repair of reinforcements (such as side members) by heat-
ing is not recommended since it may weaken the component.
When heating is unavoidable, do not heat HSS parts above
550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appro-
priate.)

When straightening body panels, use caution in pulling any
HSS panel. Because HSS is very strong, pulling may cause
deformation in adjacent portions of the body. In this case,
increase the number of measuring points, and carefully pull
the HSS panel.

When cutting HSS panels, avoid gas (torch) cutting if possi-
ble. Instead, use a saw to avoid weakening surrounding areas
due to heat. If gas (torch) cutting is unavoidable, allow a mini-
mum margin of 50 mm (1.97in).
Tensile strength Nissan/Infiniti designation Major applicable parts
373 N/mm
2
(38kg/mm2 ,54klb/sq in)SP130

Front inner pillar upper

Front pillar hinge brace

Outer front pillar reinforcement

Other reinforcements
785-981 N/mm
2
(80-100kg/mm2
114-142klb/sq in)SP150

Outer sill reinforcement

Main back pillar
PIIA0115E
PIIA0116E
PIIA0117E

BL-194
BODY REPAIR
Revision: August 20072004 QX56

Follow the specifications for the proper welding pitch.
Unit:mm
Foam RepairEIS002UB
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
URETHANE FOAM APPLICATIONS
Use commercially available spray foam for sealant (foam material) repair of material used on vehicle. Read
instructions on product for fill procedures.
FILL PROCEDURES
1. Fill procedures after installation of service part.
–Remove foam material remaining on vehicle side.
–Clean area in which foam was removed.
–Install service part.
–Insert nozzle into hole near fill area and fill foam material or fill in enough to close gap with the service
part.
2. Fill procedures before installation of service part.
–Remove foam material remaining on vehicle side.
–Clean area in which foam was removed.
–Fill foam material on wheelhouse outer side.
NOTE:
Fill in enough to close gap with service part while avoiding
flange area.
–Install service part.
NOTE:
Refer to label for information on working times.Thickness (t)
Minimum pitch ( )
0.6 (0.024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.6 (0.063)
1.8 (0.071)10 (0.39) or over
12 (0.47) or over
18 (0.71) or over
20 (0.79) or over
27 (1.06) or over
31 (1.22) or over
PIIA0148E
LIIA1081E
LIIA1082E

BODY REPAIR
BL-195
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MA
B
BL
Revision: August 20072004 QX56
Replacement OperationsEIS002UC
DESCRIPTION
This section is prepared for technicians who have attained a high level of skill and experience in repairing col-
lision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig-
inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains
additional information, including cautions and warnings, that are not including in this manual. Technicians
should refer to both manuals to ensure proper repairs.
Please note that this information is prepared for worldwide usage, and as such, certain procedures may not
apply in some regions or countries.

BL-212
BODY REPAIR
Revision: August 20072004 QX56
Installation Notes

Scribe a straight line on the inner side rail crush horn along the hole center as shown in the figure. Cut off
inner side rail crush horn along scribed line.

Scribe a straight line on the outer side rail crush horn along the hole center as shown in the figure. Cut off
outer side rail crush horn along scribed line.
LIIA1087E
LIIA1088E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
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H
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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-2Revision: August 20072004 QX56 REMOVAL ........................................................... 28
INSTALLATION .................................................... 28
Removal and Installation of Brake Caliper Assembly
and Disc Rotor ........................................................ 28
REMOVAL ........................................................... 28
INSTALLATION .................................................... 28
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 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