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BRAKE SYSTEM

F BRAKES

SECTION
BRAKE SYSTEM
BR B

E
CONTENTS
PRECAUTIONS ......................................................... 3
. INSTALLATION .................................................. 14 . BR
Precautions for Supplemental Restraint System Disassembly and Assembly ................................... 15 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- COMPONENTS .................................................. 15 .
SIONER" ................................................................. 3
. DISASSEMBLY .................................................. 15 . G
Precautions for Brake System ................................. 3 . ASSEMBLY ........................................................ 15.
PREPARATION .......................................................... 4
. BRAKE BOOSTER .................................................. 17 .
Commercial Service Tools ....................................... 4 . On-Vehicle Service ................................................ 17.
H
NOISE, VIBRATION AND HARSHNESS (NVH) OPERATING CHECK ......................................... 17 .
TROUBLESHOOTING ............................................... 5 . AIRTIGHT CHECK ............................................. 17 .
NVH Troubleshooting Chart .................................... 5 . Removal and Installation ....................................... 17 .
BRAKE PEDAL ......................................................... 6
. COMPONENTS .................................................. 17 . I
Inspection and Adjustment ...................................... 6 . REMOVAL .......................................................... 17
.
PLAY AND CLEARANCE BETWEEN BRAKE INSPECTION AFTER REMOVAL ...................... 18 .
PEDAL AND FLOOR PANEL WITH PEDAL INSTALLATION .................................................. 18 . J
DEPRESSED. ...................................................... 6
. VACUUM LINES ...................................................... 19 .
ADJUSTMENT ..................................................... 7. Removal and Installation ....................................... 19 .
Removal and Installation ......................................... 7. Inspection .............................................................. 19
.
K
COMPONENT PARTS LOCATION ...................... 7 . VISUAL INSPECTION ........................................ 19 .
REMOVAL ............................................................ 8
. CHECK VALVE INSPECTION ............................ 20 .
INSPECTION AFTER REMOVAL ........................ 8 . FRONT DISC BRAKE .............................................. 21 .
INSTALLATION .................................................... 8
. Components .......................................................... 21
. L
BRAKE FLUID ........................................................... 9
. On-Vehicle Inspection ............................................ 22 .
Checking Brake Fluid Level .................................... 9 . PAD WEAR INSPECTION .................................. 22 .
Drain and Refill ........................................................ 9
. Removal and Installation of Brake Pad ................. 22 . M
Bleeding Brake System ......................................... 10 . REMOVAL .......................................................... 22
.
BRAKE PIPING AND HOSE ....................................11 . INSTALLATION .................................................. 23 .
Hydraulic Circuit .....................................................11
. Removal and Installation of Brake Caliper Assembly
Front Brake Piping and Hose .................................11 . ... 23
REMOVAL ...........................................................11
. REMOVAL .......................................................... 23
.
INSTALLATION ...................................................11. INSTALLATION .................................................. 23 .
Rear Brake Piping and Hose ................................. 12 . Disassembly and Assembly of Brake Caliper
REMOVAL .......................................................... 12
. Assembly ............................................................... 24
.
INSTALLATION .................................................. 12. DISASSEMBLY .................................................. 24 .
Inspection After Installation ................................... 13. INSPECTION AFTER DISASSEMBLY ............... 24 .
BRAKE MASTER CYLINDER ................................. 14 . DISC ROTOR INSPECTION .............................. 25 .
On-Board Inspection ............................................. 14. ASSEMBLY ........................................................ 25.
LEAK INSPECTION ........................................... 14 . Brake Burnishing Procedure .................................. 26 .
Removal and Installation ....................................... 14 . REAR DISC BRAKE ................................................ 28 .
REMOVAL .......................................................... 14
. Component ............................................................ 28
.
On-Vehicle Inspection ............................................ 29 .

Edition: 2004 September BR-1 2005 G35 Coupe
PAD WEAR INSPECTION .................................. 29 . INSPECTION AFTER DISASSEMBLY ...............31 .
Removal and Installation of Brake pad .................. 29 . DISC ROTOR INSPECTION ..............................32 .
REMOVAL .......................................................... 29
. ASSEMBLY .........................................................32
.
INSTALLATION ................................................... 30. Brake Burnishing Procedure ..................................33 .
Removal and Installation of Brake Caliper Assembly SERVICE DATA AND SPECIFICATIONS (SDS) .....34 .
... 30 General Specifications ...........................................34.
REMOVAL .......................................................... 30
. Brake Pedal ...........................................................34
.
INSTALLATION ................................................... 30. Check Valve ...........................................................34
.
Disassembly and Assembly of Brake Caliper Brake Booster ........................................................34
.
Assembly ............................................................... 31
. Front Disc Brake ....................................................34
.
DISASSEMBLY .................................................. 31 . Rear Disc Brake .....................................................35
.

Edition: 2004 September BR-2 2005 G35 Coupe
PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" AFS002ST

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along B
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 C
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: D
q 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. E
q 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. BR
q 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.
G
Precautions for Brake System AFS002SU

q Recommended fluid is brake fluid "DOT 3".
H
q Never reuse drained brake fluid.
q Be careful not to splash brake fluid on painted areas.
q To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. I
q Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
q Use a flare nut wrench when removing a brake tube and use a
flare nut torque wrench when installing a brake tube. J
q When installing brake piping, be sure to check torque.
q Before working, turn ignition switch OFF and disconnect con-
nectors of VDC/TCS/ABS control unit or the battery cable from K
the negative terminal.
q Burnish the brake contact surfaces after refinishing or replacing
drums or rotors, after replacing pads or linings, or if a soft pedal L
occurs at very low mileage.
Refer to BR-26, "Brake Burnishing Procedure" .
SBR686C

M
WARNING:
q Collect dust on brake parts with dust collector. Do not blow off the dust.

Edition: 2004 September BR-3 2005 G35 Coupe
PREPARATION

PREPARATION PFP:00002

Commercial Service Tools AFS002SV

Tool name Description

1. Flare nut crowfoot
a:10 mm (0.39 in) (Other)
Installing brake piping
a:12 mm (0.47 in) (Between VDC
actuator and master cylinder)
2. Torque wrench
S-NT360

Removing front/rear caliper assembly
Power tool
and tire

PBIC0190E

Pin punch Removing and installing reservoir tank
Tip diameter: 4 mm (0.16 in) dia pin

ZZA0515D

Edition: 2004 September BR-4 2005 G35 Coupe
Symptom

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