Nissan FX35/FX45 Brake System

Precautions

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System (SRS), including "AIR BAG" and "SEAT BELT PRE-TENSIONER", works with front seat belts to reduce injury risk in collisions. It uses seat belt switch inputs and dual-stage front air bags. Service information is in the SRS and SB sections of this manual.

WARNING:

• To prevent SRS malfunction, which could increase injury risk in a collision, all maintenance must be done by an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect SRS removal/installation, can cause personal injury from unintentional system activation. Refer to the SRS section for Spiral Cable and Air Bag Module removal.
• Do not use electrical test equipment on SRS circuits unless specified in this manual. SRS wiring harnesses are typically yellow and/or orange.

Precautions for Brake System

• Recommended fluid: Brake fluid "DOT 3".
• Do not reuse drained brake fluid.
• Avoid splashing brake fluid on painted surfaces.
• Use clean brake fluid to clean master cylinder, disc brake caliper, and wheel cylinder parts.
• Do not use mineral oils like gasoline or kerosene, as they damage hydraulic system rubber parts.
• Use a flare nut wrench for brake tube removal/installation.
• Check torque when installing brake piping.
• Before working, turn the ignition OFF and disconnect connectors for ABS actuator, electric unit, or battery terminal.
• Burnish brake contact surfaces after refinishing/replacing rotors or pads, or if a soft pedal occurs at 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.

Preparation

Commercial Service Tools

Tools required for brake system service include:

• Flare nut crowfoot: 10 mm (0.39 in) / 12 mm (0.47 in) - Used for removing and installing brake piping.
• Torque wrench
• Power tool - Used for removing front and rear caliper assemblies and tires.

Noise, Vibration and Harshness (NVH) Troubleshooting

NVH Troubleshooting Chart

Use the following chart to identify causes of noise and vibration. Repair or replace parts as necessary.

Brake Pedal

Inspection and Adjustment

PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED

1. Check brake pedal height from the dash lower panel.

2. Adjust height according to the following specifications:

• Brake pedal free height (from dash lower panel top surface): 161.5 - 171.5 mm (6.36 - 6.75 in)
• Brake pedal depressed height (under a force of 490 N (50 kg, 110 lb) with engine running): More than 80 mm (3.15 in)
• Clearance between bracket and the threaded end of stop lamp switch or ASCD cancel switch (or brake switch): 0.74 - 1.96 mm (0.0291 - 0.0772 in)
• Pedal play: 3 - 11 mm (0.12 - 0.43 in)

Diagram description: A diagram illustrates the brake pedal mechanism, showing the input rod, lock nut, clevis pin, stopper rubber, stop lamp switch, and floor panel.

ADJUSTMENT

1. Loosen the stop lamp switch and ASCD cancel switch (or brake switch) by turning counterclockwise 45°.
2. Loosen lock nut (A) on the input rod. Rotate the input rod to set the pedal to the specified height, then tighten lock nut (A). CAUTION: Ensure the threaded end of the input rod remains inside the clevis.
3. With the pedal pulled and held by hand, press the stop lamp switch and ASCD cancel switch (or brake switch) until its threaded end contacts the stopper rubber.
4. With the switch threaded end contacting the stopper rubber, rotate the switch clockwise 45° to secure. CAUTION: Ensure clearance (C) between the stopper rubber and the switch threaded end is within the standard.
5. Check pedal play. CAUTION: Verify stop lamps turn OFF when the pedal is released.
6. Start the engine to check the brake pedal depressed height.

Removal and Installation

COMPONENT PARTS LOCATION

Diagram description: An exploded view shows the component parts of the brake pedal assembly, including the clevis pin, snap pin, stopper rubber, pedal pad, stop lamp switch, ASCD cancel switch, clip, and brake pedal assembly itself. Torque specifications are indicated for some fasteners.

REMOVAL

1. Remove the front kicking plate (driver side). Refer to EI-39, "KICKING PLATE".
2. Remove the dash side finisher (driver side). Refer to EI-38, "DASH SIDE FINISHER".
3. Remove the instrument lower panel (driver side). Refer to IP-18, "INSTRUMENT PASSENGER LOWER PANEL".
4. Remove the steering column assembly. Refer to PS-12, "Removal and Installation".
5. Remove the stop lamp switch and ASCD cancel switch (or brake switch) from the pedal assembly.
6. Remove the snap pin and clevis pin from the brake booster clevis.
7. Remove mounting nuts and bolts from the bracket, then remove the pedal assembly from the vehicle.

INSPECTION AFTER REMOVAL

• Check that rivets in the upper part of the brake pedal are not deformed.
• Ensure the sub bracket and slide plate are at least 4 mm (0.16 in) apart.
• Check the brake pedal for bends, damage, or cracks on welded parts. Replace if damaged.
• Check the clevis pin and resin stopper for damage or deformation. Replace the clevis pin if damaged.

INSTALLATION

Install in the reverse order of removal. After installing the brake pedal assembly, adjust the brake pedal height.

Brake Fluid

On-board Inspection

LEVEL CHECK

• Ensure the fluid level in the reservoir tank is between the MAX and MIN lines.
• Visually check the reservoir tank area for fluid leaks.
• If the fluid level is excessively low, check the brake system for leaks.
• If the brake warning lamp remains illuminated after releasing the parking lever, check the brake system for fluid leakage.

Diagram description: A diagram shows the brake fluid reservoir with MAX and MIN lines, indicating the correct fluid level.

Drain and Refill

CAUTION:

• Refill with new brake fluid "DOT3".
• Do not reuse drained brake fluid.
• Prevent brake fluid from splashing on painted surfaces, as it can damage paint. Wipe off spills immediately and wash with water.
• Before servicing, disconnect the actuator connector or battery negative cable.

1. Connect a vinyl tube to each bleed valve.
2. Depress the brake pedal, loosen each bleed valve, and gradually remove brake fluid.
3. Ensure no foreign material is in the reservoir tank, then refill with new brake fluid.
4. With foot on brake pedal, loosen bleed valve. Slowly depress pedal until it stops. Tighten bleed valve. Release pedal. Repeat this process several times, adding new brake fluid to the master cylinder as needed. Continue until new fluid flows out. Bleed air. Refer to BR-10, "Bleeding Brake System".

Diagram description: A diagram shows a brake bleed valve with a vinyl tube attached, illustrating the process of draining brake fluid.

Bleeding Brake System

CAUTION:

Monitor the master cylinder fluid level during bleeding.

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. Depress the brake pedal 4 to 5 times.
4. With the brake pedal depressed, loosen the bleed valve to let air out, then tighten it immediately.
5. Repeat steps 3 and 4 until no more air is expelled.
6. Tighten the bleed valve to the specified torque. Refer to BR-20, "Components" (front disc brake) and BR-25, "Components" (rear disc brake).
7. Following steps 2 to 6, with the master cylinder reservoir tank at least half full, bleed air from the front left, rear left, and front right bleed valves, in that order.

Brake Piping and Hose

Hydraulic Circuit

Diagram description: A schematic illustrates the hydraulic circuit of the brake system, showing the master cylinder, brake booster, ABS actuator, connectors, and brake lines. Torque specifications are provided for flare nuts and union bolts.

CAUTION:

• All hoses and piping must be free from excessive bending, twisting, and pulling.
• Ensure no interference with other parts when steering.
• Brake piping is a critical safety component. If a leak is detected, disassemble and replace the affected part.
• Avoid splashing brake fluid on painted areas; wash spills immediately with water.
• Do not bend or twist brake hoses sharply, or pull them strongly.
• When removing components, cover connections to prevent dirt ingress.
• Refill with new brake fluid "DOT 3".
• Do not reuse drained brake fluid.

Removal and Installation of Front Brake Piping and Brake Hose

REMOVAL

1. Drain brake fluid. Refer to BR-9, "Drain and Refill".
2. Using a flare nut wrench, remove the brake tube from the brake hose.
3. Remove the union bolt and remove the brake hose from the caliper assembly.
4. Remove the lock plate and remove the brake hose from the vehicle.

INSTALLATION

1. Install the brake hose, aligning it with the caliper assembly protrusion, and tighten the union bolt to the specified torque. NOTE: Do not reuse the copper washer.
2. Install the brake hose to the brake tube. Partially tighten the flare nut by hand, then secure it to the bracket with the lock plate.
3. Using a flare nut wrench, tighten the flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".

Removal and Installation of Rear Brake Piping and Brake Hose

REMOVAL

1. Drain brake fluid. Refer to BR-9, "Drain and Refill".
2. Using a flare nut wrench, remove the brake tube from the brake hose.
3. Remove the bolt.
4. Remove the union bolt, then remove the brake hose from the caliper assembly.

INSTALLATION

1. Install the brake hose to the caliper assembly positioning hole and tighten the union bolt to the specified torque. NOTE: Do not reuse the copper washer.
2. Install the brake hose to the brake tube. Partially tighten the flare nut by hand, then tighten the bolt to the specified torque (23.5 N·m / 2.4 kg-m / 17 ft-lb).
3. Using a flare nut wrench, tighten the flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".

Inspection After Installation

CAUTION:

If a leak is detected at connections, retighten or replace the damaged part.

1. Check brake lines (tubes and hoses) and connections for fluid leaks, damage, twist, deformation, contact with other parts, and loose connections. Replace any damaged parts.
2. While depressing the brake pedal with a force of 785 N (80 kg, 177 lb) for approximately 5 seconds with the engine running, check for fluid leakage from each part.

Brake Master Cylinder

On-board Inspection

LEAK INSPECTION

• Check for leaks at the master cylinder attachment, reservoir tank, and brake tube connections.

Removal and Installation

CAUTION:

Be careful not to splash brake fluid on painted areas, as it can damage paint. Wash spills immediately with water.

REMOVAL

1. Drain brake fluid. Refer to BR-9, "Drain and Refill".
2. Disconnect harness connectors for the fluid level sensor and pressure sensor.
3. Using a flare nut wrench, disconnect the brake tube from the master cylinder assembly.
4. Remove the master cylinder assembly fixing nut, then remove the master cylinder assembly from the vehicle. Refer to BR-16, "Removal and Installation".

INSTALLATION

• Install in the reverse order of removal.
• Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".

CAUTION:

• Refill with new brake fluid "DOT3".
• Do not reuse drained brake fluid.

Components

Diagram description: An exploded view shows the components of the brake master cylinder assembly, including the reservoir cap, reservoir tank, strainer, grommet, float, master cylinder sub-assembly, clip, and pressure sensor. Torque specifications and lubrication points are indicated.

Disassembly and Assembly

DISASSEMBLY

CAUTION:

• The master cylinder cannot be disassembled.
• Remove the reservoir tank only when absolutely necessary.

1. Remove the clip.
2. Remove the reservoir tank and grommet from the master cylinder assembly.

ASSEMBLY

CAUTION:

• Do not use mineral oils like kerosene or gasoline during cleaning and assembly.
• Do not drop parts. If a part is dropped, do not use it.

1. Apply brake fluid to the grommet and attach it to the master cylinder assembly. CAUTION: Do not reuse the grommet.
2. Install the reservoir tank onto the master cylinder assembly.
3. Install the clip.

Brake Booster

On-vehicle Service

OPERATING CHECK

With the engine stopped, change vacuum to atmospheric pressure by depressing the brake pedal several times. Then, with the brake pedal fully depressed, start the engine. When vacuum pressure reaches the standard, the clearance between the brake pedal and floor panel should decrease.

CAUTION:

Depressing pedal interval should be approximately 5 seconds.

Diagram description: A sequence of diagrams illustrates the operating check of the brake booster, showing pedal depression and engine start, and the resulting change in pedal clearance.

AIRTIGHT CHECK

• Run the engine at idle for approximately 1 minute, then stop it after applying vacuum to the booster. Depress the brake pedal normally to change the vacuum to atmospheric pressure. The distance between the brake pedal and floor panel should gradually increase.
• Depress the brake pedal while the engine is running, then stop the engine with the pedal depressed. The pedal stroke should not change after holding the pedal down for 30 seconds.

CAUTION:

Depressing pedal interval should be approximately 5 seconds.

Diagram description: Diagrams show the 'OK' and 'NG' conditions for the airtight check, illustrating pedal movement and the expected outcome.

Removal and Installation

Components

Diagram description: An illustration shows the brake booster assembly and its related components, including the reservoir tank, master cylinder, gasket, brake pedal, lock nut, and brake booster itself. Torque specifications are provided.

REMOVAL

CAUTION:

• Be careful not to deform or bend brake piping during removal and installation.
• Replace the clevis pin if it is damaged.
• Do not damage brake booster stud bolt threads. Tilting or inclining the booster during installation can damage dash panel threads.
• Attach the check valve in the correct direction.

1. Remove brake piping from the brake master cylinder.
2. Remove the brake master cylinder. Refer to BR-13, "Removal and Installation".
3. Remove the vacuum hose from the brake booster. Refer to BR-18, "VACUUM LINES".
4. Disconnect the harness connector from the brake booster assembly (ICC model).
5. Remove the brake pedal attachment snap pin and clevis pin from inside the vehicle.
6. Remove nuts on the brake booster and brake pedal assembly.
7. Remove the brake booster assembly from the dash panel.

INSPECTION AFTER REMOVAL

Output Rod Length Inspection

1. Using a vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake booster.
2. Check the output rod length.

Standard dimension when vacuum: -66.7 kPa (-500 mmHg, -19.69 inHg): 15.6 – 15.9 mm (0.614 – 0.626 in)

Diagram description: A diagram shows how to measure the output rod length of the brake booster using a vacuum pump.

INSTALLATION

1. Loosen the lock nut to adjust the input rod length so that length 'B' (as shown in the figure) meets the specified value: 125 mm (4.92 in).
2. After adjusting 'B', temporarily tighten the lock nut to install the booster assembly to the vehicle. Ensure a gasket is installed between the booster assembly and the dash panel.
3. Connect the brake pedal to the input rod clevis.
4. Install the pedal bracket mounting nuts and tighten them to the specified torque.
5. Install brake piping from the brake master cylinder to the ABS actuator. Refer to BR-11, "Hydraulic Circuit".
6. Install the master cylinder to the booster assembly. Refer to BR-16, "Removal and Installation".
7. Adjust the height and play of the brake pedal.
8. Tighten the input rod lock nut to the specified torque.
9. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".

Vacuum Lines

Removal and Installation

Diagram description: Two diagrams illustrate the vacuum line routing for VK45DE and VQ35DE models, showing clamps, vacuum piping, vacuum hose, check valve, and the brake booster.

CAUTION:

• Vacuum hoses contain a check valve and must be installed in the correct direction, indicated by stamps or labels. Incorrect installation will prevent the brake booster from operating correctly.
• Insert vacuum hose at least 24 mm (0.94 in).
• Do not use lubricating oil during assembly.

Inspection

VISUAL INSPECTION

Check for improper assembly, damage, and deterioration.

Diagram description: A diagram shows the correct insertion depth for a vacuum hose, indicating it should contact a protrusion on the vacuum tube.

CHECK VALVE INSPECTION

Airtightness Inspection

Use a handy vacuum pump for testing.

• When connected to booster side (1): Vacuum decrease should be within 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds under a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg).
• When connected to engine side (2): No vacuum will be applied.

Diagram description: A diagram illustrates the check valve inspection setup, showing connections to the engine side and booster side with a vacuum pump.

Front Disc Brake

On-vehicle Inspection

PAD WEAR INSPECTION

Inspect pad thickness through the cylinder body inspection hole. Use a scale if necessary.

• Standard thickness: 9.5 mm (0.374 in)
• Repair limit thickness: 2.0 mm (0.079 in)

Components

Diagram description: An exploded view details the components of the front disc brake caliper assembly, including union bolt, copper washer, brake hose, sliding pin bolt, sliding pin, cap, bleed valve, cylinder body, sliding pin boot, piston seal, piston, piston boot, torque member, inner shim cover, inner shim, inner pad, pad retainer (upper and lower), outer pad, outer shim, and torque member bolt. Torque specifications and replacement notes are provided.

Removal and Installation of Brake Pad

REMOVAL

1. Remove tires from the vehicle using a power tool.
2. Remove the lower sliding pin bolt.
3. Suspend the cylinder body with a wire and remove the pad and shim from the torque member.

INSTALLATION

1. Attach the inner shim and shim cover to the inner pad, and the outer shim to the outer pad.
2. Push the piston in so the pad is firmly installed, then mount the cylinder body to the torque member. NOTE: A disc brake piston tool is recommended. CAUTION: Pushing in the piston returns brake fluid to the master cylinder reservoir; monitor its level.
3. Attach the pad retainer to the torque member. CAUTION: Ensure the pad retainer is firmly attached and does not float up higher than the torque member.
4. Install the lower sliding pin bolt and tighten to the specified torque.
5. Check for brake drag.
6. Attach tires to the vehicle.

Removal and Installation of Brake Caliper Assembly

REMOVAL

1. Remove tires from the vehicle using a power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill".
3. Remove union bolts and torque member bolts, then remove the brake caliper assembly from the vehicle.
4. Remove the disc rotor.

INSTALLATION

CAUTION:

• Refill with new brake fluid "DOT3".
• Do not reuse drained brake fluid.

1. Install the disc rotor.
2. Install the caliper assembly to the vehicle and tighten bolts to the specified torque. CAUTION: Wipe any oil off the knuckle spindle, washers, and caliper assembly attachment surfaces before installation.
3. Install the brake hose to the brake caliper assembly and tighten the union bolt to the specified torque. CAUTION: Do not reuse copper washers for the union bolt. Securely attach the brake hose to the caliper assembly protrusion with the union bolt and washers.
4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".
5. Attach tires to the vehicle.

Disassembly and Assembly of Brake Caliper Assembly

DISASSEMBLY

1. Remove the sliding pin bolt, then remove the pad, shim, shim cover, and pad retainer from the torque member.
2. Remove the sliding pins and sliding pin boots from the torque member.
3. Using a flat-bladed screwdriver, remove the retaining ring from the cylinder body.
4. Place a wooden block as shown in the figure, and blow air from the union bolt mounting hole to remove pistons and piston boots. CAUTION: Do not get your fingers caught in the piston.
5. Using a flat-bladed screwdriver, remove the piston seals from the cylinder body. CAUTION: Be careful not to damage the cylinder inner wall.

Diagram description: Illustrations show the process of removing the retaining ring from the cylinder body and removing pistons/boots using compressed air, with a warning about finger entrapment. Another diagram shows removing piston seals.

CALIPER INSPECTION

Cylinder Body

CAUTION:

• Use new brake fluid for cleaning. Do not use mineral oils like gasoline or kerosene.
• Check the inside surface of the cylinder for score, rust, wear, damage, or foreign materials. Replace the cylinder body if any of these conditions are observed.
• Minor damage from rust or foreign materials can be removed by polishing with fine emery paper. Replace the cylinder body if necessary.

Torque Member

Check for wear, cracks, and damage. Replace the affected part if damaged or deformed.

Piston

Check the piston for score, rust, wear, damage, or foreign materials. Replace if any conditions are observed. CAUTION: The piston sliding surface is plated; do not polish it, even if rust or foreign materials are present.

Sliding Pins and Sliding Pin Boots

Check sliding pins and boots for wear, damage, or cracks. Replace if any are present.

ASSEMBLY

CAUTION:

Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) during assembly.

1. Apply rubber grease to the new piston seal and insert it into the groove on the cylinder body. CAUTION: Do not reuse the piston seal.
2. Apply brake fluid to the piston and rubber grease to the piston boot, then install the piston boot into the piston groove. CAUTION: Do not reuse the piston boot.
3. Insert the piston into the cylinder body by hand, and insert the piston boot's piston-side lip into the piston groove. CAUTION: Press the piston evenly and vary the pressing point to avoid rubbing the cylinder inner wall.
4. Install sliding pins and sliding pin boots to the torque member.
5. Attach the inner shim and inner shim cover to the inner pad, and the outer shim and outer shim cover to the outer pad.
6. Install the cylinder body. Tighten the sliding pin bolt to the specified torque.

Diagram description: Illustrations show applying rubber grease to a piston seal, installing a piston boot onto a piston, and pressing the piston into the cylinder body.

DISC ROTOR INSPECTION

Visual Inspection

Check the disc rotor surface for uneven wear, cracks, and serious damage. Replace applicable parts if any non-standard condition is detected.

Runout Inspection

1. Using wheel nuts, fix the disc rotor to the wheel hub (2 or more positions).
2. Inspect runout using a dial gauge, measured at 10 mm (0.39 in) inside the disc edge.
3. Runout limit (with it attached to the vehicle): 0.04 mm (0.0016 in)
4. Runout limit (just the disc rotor): 0.02 mm (0.0008 in)
5. NOTE: Ensure wheel bearing axial endplay is within specifications before measuring runout. Refer to FAX-4, "On-Vehicle Inspection and Service".
6. If runout exceeds the limit, find the minimum runout point by shifting the mounting positions of the disc rotor and wheel hub by one hole.
7. If runout is still out of specification, turn the rotor with an on-car brake lathe (e.g., "MAD DL-8700", "AMMCO 700 and 705" or equivalent).

Diagram description: A diagram shows the process of measuring disc rotor runout using a dial gauge.

Thickness Inspection

Using a micrometer, check disc rotor thickness. Replace the disc rotor if thickness is outside the standard.

• Standard thickness: 28.0 mm (1.102 in)
• Repair limit thickness: 26.0 mm (1.024 in)
• Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 in)

Diagram description: A diagram illustrates checking disc rotor thickness with a micrometer.

BRAKE BURNISHING PROCEDURE

Burnish brake contact surfaces after refinishing/replacing rotors or pads, or if a soft pedal occurs at very low mileage, using the following procedure.

CAUTION:

Perform this procedure only under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight, smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust pedal pressure so stopping time is 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Rear Disc Brake

On-vehicle Inspection

PAD WEAR INSPECTION

Inspect pad thickness through the cylinder body inspection hole. Use a scale if necessary.

• Standard thickness: 8.5 mm (0.335 in)
• Repair limit thickness: 2.0 mm (0.079 in)

Components

Diagram description: An exploded view details the components of the rear disc brake caliper assembly, including union bolt, brake hose, copper washer, cap, bleed valve, sliding pin bolt, cylinder body, piston seal, piston, piston boot, retaining ring, torque member, torque member bolt, sliding pin boot, inner shim cover, inner shim, inner pad, pad retainer, outer pad, outer shim, and outer shim cover. Torque specifications and replacement notes are provided.

Removal and Installation of Brake Pad

REMOVAL

1. Remove tires from the vehicle using a power tool.
2. Remove the sliding pin bolt (one on top).
3. Suspend the cylinder body with a wire, and remove pads, pad retainers, and shims from the torque member.

INSTALLATION

1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the pad backside and shim sides. Attach inner shim and cover to the inner pad, and outer shim and cover to the outer pad.
2. Install the pad retainer and mount the pad to the torque member.
3. Push the piston in so the pad is firmly attached, then mount the cylinder body to the torque member. NOTE: A disc brake piston tool is recommended. CAUTION: Pushing in the piston returns brake fluid to the master cylinder reservoir; monitor its level.
4. Install the sliding pin bolt (one on top) and tighten to the specified torque.
5. Check for brake drag.
6. Install tires to the vehicle.

Removal and Installation of Brake Caliper Assembly

REMOVAL

1. Remove tires from the vehicle using a power tool.
2. Drain brake fluid. Refer to BR-9, "Drain and Refill".
3. Remove union bolt and torque member bolts, then remove the brake caliper assembly from the vehicle.
4. Remove the disc rotor.

INSTALLATION

CAUTION:

• Refill with new brake fluid "DOT3".
• Do not reuse drained brake fluid.

1. Install the disc rotor.
2. Install the caliper assembly to the vehicle and tighten bolts to the specified torque. CAUTION: Before installing, wipe off oil and grease on washer seats on the axle assembly and mounting surface of the caliper assembly.
3. Install the brake hose to the caliper assembly and tighten the union bolt to the specified torque. CAUTION: Do not reuse copper washers for the union bolt. Securely attach the brake hose to the protrusion on the caliper assembly.
4. Refill new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System".
5. Install tires to the vehicle.

Disassembly and Assembly of Brake Caliper Assembly

DISASSEMBLY

1. Remove the sliding pin bolt, then remove the pad, shim, shim cover, and pad retainer from the torque member and cylinder.
2. Remove the sliding pin boot from the torque member.
3. Using a flat-bladed screwdriver, remove the retaining ring from the cylinder body.
4. Place a wooden block as shown in the figure, and blow air from the union bolt mounting hole to remove pistons and piston boots. CAUTION: Do not get your fingers caught in the piston.
5. Using a flat-bladed screwdriver, remove piston seals from the cylinder body. CAUTION: Be careful not to damage the cylinder inner wall.

Diagram description: Illustrations show removing a retaining ring from the cylinder body, removing pistons and boots using compressed air (with a warning), and removing piston seals.

CALIPER INSPECTION

Cylinder Body

CAUTION:

• Use new brake fluid for cleaning. Do not use mineral oils like gasoline or kerosene.
• Check the inside surface of the cylinder for score, rust, wear, damage, or foreign materials. Replace the cylinder body if any of these conditions are observed.
• Minor damage from rust or foreign materials can be removed by polishing with fine emery paper. Replace the cylinder body if necessary.

Torque Member

Check for wear, cracks, and damage. Replace the affected part if damaged or deformed.

Piston

Check the piston for score, rust, wear, damage, or foreign materials. Replace if any conditions are observed. CAUTION: The piston sliding surface is plated; do not polish it, even if rust or foreign materials are present.

Sliding Pin Bolts and Sliding Pin Boots

Check sliding pins and boots for wear, damage, or cracks. Replace if any are present.

ASSEMBLY

CAUTION:

Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) during assembly.

1. Apply rubber grease to the new piston seal and insert it into the groove on the cylinder body. CAUTION: Do not reuse the piston seal.
2. Apply brake fluid to the piston and rubber grease to the piston boot, then install the piston boot into the piston groove. CAUTION: Do not reuse the piston boot.
3. Insert the piston into the cylinder body by hand, and insert the piston boot's piston-side lip into the piston groove. CAUTION: Press the piston evenly and vary the pressing point to avoid rubbing the cylinder inner wall.
4. Fix the piston boot with the retaining ring. CAUTION: Ensure the boot is firmly in the cylinder body groove. Do not reuse the retaining ring.
5. Install sliding pin bolt and sliding pin boots to the torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to the pad backside and shim sides. Attach inner shim and cover to the inner pad, and outer shim and cover to the outer pad.
7. Assemble shims and shim covers to the pad.
8. Attach the pad retainer and pad to the torque member.
9. Install the cylinder body. Tighten the sliding pin bolts to the specified torque.

Diagram description: Illustrations show applying rubber grease to a piston seal, installing a piston boot, and securing a piston boot with a retaining ring.

DISC ROTOR INSPECTION

Visual Inspection

Check the disc rotor surface for uneven wear, cracks, and serious damage. Replace applicable parts if any non-standard condition is detected.

Runout Inspection

1. Using wheel nuts, fix the disc rotor to the wheel hub (2 or more positions).
2. Inspect runout using a dial gauge, measured at 10 mm (0.39 in) inside the disc edge.
3. Runout limit (with it attached to the vehicle): 0.05 mm (0.0020 in)
4. NOTE: Ensure wheel bearing axial endplay is within specifications before measuring runout. Refer to RAX-5, "On-Vehicle Inspection and Service".
5. If runout exceeds the limit, find the minimum runout point by shifting the mounting positions of the disc rotor and wheel hub by one hole.
6. If runout is still out of specification, turn the rotor with an on-car brake lathe (e.g., "MAD, DL-8700", "AMMCO 700 and 705" or equivalent).

Diagram description: A diagram shows the process of measuring disc rotor runout using a dial gauge.

Thickness Inspection

Using a micrometer, check disc rotor thickness. Replace the disc rotor if thickness is outside the standard.

• Standard thickness: 16.0 mm (0.630 in)
• Wear limit: 14.0 mm (0.551 in)
• Maximum uneven wear (measured at 8 positions): 0.015 mm (0.0006 in)

Diagram description: A diagram illustrates checking disc rotor thickness with a micrometer.

BRAKE BURNISHING PROCEDURE

Burnish brake contact surfaces after refinishing/replacing rotors or pads, or if a soft pedal occurs at very low mileage, using the following procedure.

CAUTION:

Perform this procedure only under safe road and traffic conditions. Use extreme caution.

1. Drive the vehicle on a straight, smooth road at 50 km/h (31 MPH).
2. Use medium brake pedal effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust pedal pressure so stopping time is 3 to 5 seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure.

Service Data and Specifications (SDS)

General Specifications

Brake Pedal

Brake Booster

Check Valve

Front Disc Brake

Rear Disc Brake