BR-1

BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
A
B
BR
Revision: August 2007 2004 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 ........................................................ ... 15
INSTALLATION ................................................ ... 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-2 Revision: August 2007 2004 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 .............. ... 31
SERVICE 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
PRECAUTIONS
BR-3
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A
B
BR
Revision: August 2007 2004 QX56
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT
BELT PRE-TENSIONER EFS003P3
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:
G 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.
G 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.
G 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 System EFS0062U
G Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" for recommended brake fluid.
G Do not reuse drained brake fluid.
G Be careful not to splash brake fluid on painted areas.
G To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
G Do not use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
G Use flare nut wrench when removing and installing brake tube.
G Always check tightening torque when installing brake lines.
G Before working, turn ignition switch to OFF and disconnect con-
nectors for ABS actuator and electric unit (control unit) or battery
terminals.
G 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-25, "BRAKE BURNISH-
ING PROCEDURE" .
WARNING:
G Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
SBR686C
BR-4
PREPARATION
Revision: August 2007 2004 QX56
PREPARATION PFP:00002
Special Service Tool EFS0062T
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service Tools EFS003P5
Tool number
(Kent-Moore No.)
Tool name
Description

(J-46532)
Brake and clutch pedal height measure-
ment tool
Measuring brake pedal height.
LFIA0227E
Tool name Description
1. Flare nut crowfoot
2. Torque wrench
Removing and installing brake piping.
a: 10 mm (0.39 in) / 12 mm (0.47 in)
Power tool Removing bolts, nuts, and screws.
S-NT360
PBIC0190E
PBIC0191E
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
BR-5
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BR
Revision: August 2007 2004 QX56
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart EFS003P6
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
: Applicable
Reference page
B
R
-
2
1
,

B
R
-
2
7
B
R
-
2
1
,

B
R
-
2
7
B
R
-
2
1
,

B
R
-
2
7
B
R
-
2
5
,

B
R
-
3
0
B
R
-
2
5
,

B
R
-
3
0
B
R
-
2
5
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B
R
-
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0
B
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-
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5
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B
R
-
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0
B
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-
2
5
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B
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-
3
0
B
R
-
2
5
,

B
R
-
3
1
B
R
-
2
5
,

B
R
-
3
1



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Possible cause and
SUSPECTED PARTS
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W
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E
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I
N
G
Symptom
Noise
Shake
Shimmy, Shudder
BR-6
BRAKE PEDAL
Revision: August 2007 2004 QX56
BRAKE PEDAL PFP:46501
Inspection and Adjustment EFS003P7
INSPECTION
1. Inspect the brake pedal free height "H" from the lower dash panel using tool.
2. Adjust the height referring to the following specifications.
CAUTION:
The adjustable pedal must be in the forwardmost (closest to
the floor) position for pedal height measurement.
Brake Pedal Specifications
Tool number : (J-46532)
WFIA0160E
Free height "H" : 182.3 - 192.3 mm (7.18 - 7.57 in)
Depressed pedal height "D" [under a force of 490 N (50 kg, 110 lb) with engine
running]
: More than 90.3 mm (3.55 in)
Clearance between pedal stopper and threaded end of stop lamp switch and
ASCD switch "C"
: 0.74 - 1.96 mm (0.029 - 0.077 in)
Pedal play "A" : 3 - 11 mm (0.12 - 0.43 in)
BRAKE PEDAL
BR-7
C
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A
B
BR
Revision: August 2007 2004 QX56
ADJUSTMENT
1. Loosen the stop lamp switch and ASCD switch by turning 45 counterclockwise.
2. Loosen lock nut on the input rod, then turn input rod to adjust the
pedal to specified height. When finished adjusting, tighten lock
nut.
CAUTION:
Make sure that the screw portion of the end of input rod is
located inside the clevis.
3. With the pedal pulled up and held by hand, press the stop lamp
switch and the ASCD switch in until threaded ends contact pedal
arm.
4. With the threaded ends of the stop lamp switch and ASCD
switch contacting the pedal arm, turn the switches 45 clockwise
to lock in place.
CAUTION:
Make sure that the gap (C) between the rubber stops and
switch ends are within specification.
5. Check the pedal play.
CAUTION:
Make sure that the stop lamp goes off when the pedal is
released.
6. Start the engine and check the height of the brake pedal when
depressing it.
Lock nut : 18.5 Nm (1.9 kg-m, 14 ft-lb)
PFIA0436E
BR-8
BRAKE PEDAL
Revision: August 2007 2004 QX56
Removal and Installation EFS003P8
REMOVAL
WARNING:
Do not deform the brake tube.
CAUTION:
G Before removal and installation the accelerator and brake pedals must be in the forward most
position (closest to the floor). This is to align the base position of the accelerator and brake ped-
als.
G Do not disassemble the brake pedal adjusting mechanism.
G Avoid damage from dropping the brake pedal assembly during handling.
G Keep the brake pedal assembly away from water.
1. Remove the lower driver instrument panel. Refer to IP-13, "Instrument Lower Cover LH" .
2. Remove the stop lamp switch and ASCD switch from the pedal assembly.
1. Brake pedal assembly 2. Snap pin 3. Clip
4. Stop lamp switch 5. Pedal pad 6. Clevis pin
7. ASCD cancel switch
WFIA0232E
BRAKE PEDAL
BR-9
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BR
Revision: August 2007 2004 QX56
3. Disconnect the adjustable brake pedal cable from the adjustable
pedal electric motor.
G Unlock (1) then pull (2) the adjustable brake pedal cable to
disconnect it from the adjustable pedal electric motor as
shown.
4. Remove snap pin and clevis pin from the clevis of brake booster.
5. Remove mounting nuts and the pedal assembly.
G Temporarily install nuts by hand to support booster.
CAUTION:
G Before removal and installation the accelerator and brake
pedals must be in the forwardmost position (closest to
the floor). This is to align the base position of the accelerator and brake pedals.
G Do not disassemble the brake pedal adjusting mechanism.
G Avoid damage from dropping the brake pedal assembly during handling.
G Keep the brake pedal assembly away from water.
INSPECTION AFTER REMOVAL
Check brake pedal for following items.
G Crack or deformation of clevis pin stopper
G Clevis pin deformation
G Crack of any welded portion
G Brake pedal bend
INSTALLATION
1. Installation is in the reverse order of removal.
G Check the brake pedal for smooth operation. There should be no binding or sticking when applying or
releasing the brake pedal.
G Check the brake pedal adjustable feature for smooth operation. There should be no binding or sticking
when adjusting the brake pedal forward or backward.
G After installing the brake pedal assembly in the vehicle, be sure to adjust it. Refer to BR-6, "Inspection and
Adjustment" .
LBIA0374E
SBR997
BR-10
BRAKE FLUID
Revision: August 2007 2004 QX56
BRAKE FLUID PFP:KN100
On-board Inspection EFS003P9
LEVEL CHECK
G Make sure the fluid level in reservoir tank is within the standard
(between MAX and MIN lines).
G Visually check around reservoir tank for fluid leaks.
G If fluid level is excessively low, check brake system for leaks.
G If brake warning lamp remains illuminated after parking lever is
released, check brake system for fluid leakage.
Drain and Refill EFS003PA
CAUTION:
G Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
G Do not reuse drained brake fluid.
G 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.
G 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 from brake system. Refer to BR-11, "Bleeding Brake
System" .
LFIA0225E
SBR419C
SBR995
BRAKE FLUID
BR-11
C
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A
B
BR
Revision: August 2007 2004 QX56
Bleeding Brake System EFS003PB
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 cable.
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 and 4 until no more air comes out.
6. Tighten bleed valve to the specified torque. Refer to BR-21, "Components" (front disc brake), BR-27,
"Components" (rear disc brake).
7. Repeat steps 2 through 6, with master cylinder reservoir tank filled at least half way, bleed air from the
front left, rear left, and front right bleed valve.
BR-12
BRAKE PIPING AND HOSE
Revision: August 2007 2004 QX56
BRAKE PIPING AND HOSE PFP:46210
Hydraulic Circuit EFS003PC
CAUTION:
G All hoses and tubes must be free from excessive bending, twisting and pulling.
G Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.
G 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.
G 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.
G Do not bend or twist brake hose sharply, or strongly pull it.
G When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.
G Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
G Do not reuse drained brake fluid.
Removal and Installation of Front Brake Hose EFS003PD
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt and then remove brake hose from caliper assembly.
1. Actuator 2. Master cylinder 3. Brake booster
4. Connector
WFIA0278E
BRAKE PIPING AND HOSE
BR-13
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BR
Revision: August 2007 2004 QX56
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt.
CAUTION:
Do not reuse copper washer.
2. Insert brake hose end through bracket, then secure it to bracket
with lock plate.
3. Install brake tube to brake hose, then tighten flare nut using a
flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake
System" .
Removal and Installation of Rear Brake Hose EFS003PE
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove lock plate and brake hose from bracket.
4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper
assembly, and tighten union bolt.
CAUTION:
Do not reuse copper washers.
2. Insert brake hose end through bracket, then secure it to bracket
with lock plate.
3. Install brake tube to brake hose, then tighten flare nut to using a
flare nut wrench.
4. Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake
System" .
LFIA0214E
LFIA0213E
LFIA0212E
LFIA0213E
BR-14
BRAKE PIPING AND HOSE
Revision: August 2007 2004 QX56
Inspection After Installation EFS003PF
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake tubes and hose connections for fluid leaks, damage, twist, deformation, contact with other
parts, and loose connections. Replace any damage parts.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately
5 seconds, check for fluid leakage from each part.
BRAKE MASTER CYLINDER
BR-15
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BR
Revision: August 2007 2004 QX56
BRAKE MASTER CYLINDER PFP:46010
On-board Inspection EFS003PG
LEAK INSPECTION
G Check for leaks at brake master cylinder to brake booster attachment point, reservoir tank, and brake tube
connections.
Removal and Installation EFS003PH
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
REMOVAL
1. Drain brake fluid. Refer to BR-10, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensors.
3. Using a flare nut wrench, disconnect brake tube from brake master cylinder.
4. Remove brake master cylinder mounting nuts, and master cylinder assembly.
1. Reservoir cap 2. Fluid level sensor 3. Grommet
4. Master cylinder sub-assembly 5. Front pressure sensor 6. Rear pressure sensor
7. Reservoir tank 8. Seal
WFIA0378E
BR-16
BRAKE MASTER CYLINDER
Revision: August 2007 2004 QX56
INSTALLATION
G Installation is in the reverse order of removal.
G Refill brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
CAUTION:
G Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
G Do not reuse drained brake fluid.
G Adjust brake pedal. Refer to BR-7, "ADJUSTMENT" .
Disassembly and Assembly EFS003PI
DISASSEMBLY
CAUTION:
G Master cylinder cannot be disassembled.
G Remove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY
CAUTION:
G Never use mineral oil such as kerosene, gasoline during the cleaning and assembly process.
G Do not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid or rubber grease to new grommets, then insert into master cylinder sub-assembly. Refer
to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
CAUTION:
Do not reuse grommet.
2. Install reservoir tank onto master cylinder sub-assembly.
BRAKE BOOSTER
BR-17
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BR
Revision: August 2007 2004 QX56
BRAKE BOOSTER PFP:47200
On-Vehicle Service EFS003PJ
OPERATING CHECK
With engine stopped, change the vacuum to the atmospheric pres-
sure by depressing brake pedal several times. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the standard, make sure the clearance between brake pedal
and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
AIRTIGHT CHECK
G Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure dis-
tance between brake pedal and floor panel gradually increases.
G Depress brake pedal while engine is running and stop engine
with pedal depressed. The pedal stroke should not change after
holding pedal down for 30 seconds.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
BRA0037D
SBR365AA
BR-18
BRAKE BOOSTER
Revision: August 2007 2004 QX56
Removal and Installation EFS003PK
REMOVAL
CAUTION:
G Be careful not to deform or bend brake piping while removing and installing brake booster.
G Replace clevis pin if it is damaged.
G Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, dash panel may damage the threads.
G Attach the check valve in the correct direction.
1. Remove engine room cover with power tool. Refer to EM-11, "Removal and Installation" .
2. Remove engine air duct assembly. Refer to EM-14, "Removal and Installation" .
3. Remove brake piping from brake master cylinder.
4. Remove brake master cylinder. Refer to BR-15, "Removal and Installation" .
5. Remove vacuum hose from brake booster. Refer to BR-20, "VACUUM LINES" .
6. Disconnect active boost and delta stroke sensor harness connectors from brake booster assembly.
7. Remove brake pedal attachment snap pin and clevis pin from inside the vehicle.
8. Remove nuts on brake booster and brake pedal assembly.
9. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of 66.7 kPa (
500 mmHg, 19.69 inHg) to brake booster.
2. Check output rod length.
1. Reservoir tank 2. Brake master cylinder 3. Gasket
4. Brake pedal 5. Lock nut 6. Spacer block
7. Brake booster 8. Active booster 9. Delta stroke sensor
WFIA0233E
Standard dimension when
vacuum 66.7 kPa ( 500
mmHg, 19.69 inHg)
: 15.6 15.9 mm
(0.614 0.626 in)
SBR208E
BRAKE BOOSTER
BR-19
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INSTALLATION
1. Loosen lock nut to adjust input rod length so that the length B (in
the figure) satisfies the specified value.
2. After adjusting B, temporarily tighten lock nut and install
booster assembly to the vehicle.
G Install a gaskets and spacer block between booster assembly
and the dash panel.
3. Connect brake pedal with clevis of input rod.
4. Install pedal bracket mounting nuts and tighten them to the
specified torque.
5. Install brake piping from brake master cylinder to ABS actuator. Refer to BR-12, "Hydraulic Circuit" .
6. Connect active boost and delta stroke sensor harness connectors to brake booster assembly.
7. Connect vacuum hose to brake booster.
8. Install master cylinder to booster assembly. Refer to BR-18, "Removal and Installation" .
9. Adjust the height and play of brake pedal.
10. Tighten lock nut of input rod to the specified torque.
11. Install engine air duct assembly. Refer to EM-14, "Removal and Installation" .
12. Install engine room cover with power tool. Refer to EM-11, "Removal and Installation" .
13. Refill with new brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
Length B : 125 mm (4.92 in)
SGIA0060E
BR-20
VACUUM LINES
Revision: August 2007 2004 QX56
VACUUM LINES PFP:41920
Removal and Installation EFS003PL
1. Disconnect vacuum hose from hose clip.
2. Release clamps and disconnect vacuum hose.
3. Remove check valve from brake booster.
4. Installation is in the reverse order of removal.
CAUTION:
G Insert vacuum hose for at least 24 mm (0.94 in).
G Do not use lubricating oil during assembly.
Inspection EFS003PM
VISUAL INSPECTION
Check for improper assembly, damage and deterioration.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a suitable vacuum pump to check. Connect to brake booster
side of check valve.
1. Hose clip 2. Clamp 3. Vacuum hose
4. Check valve
LFIA0216E
SBR225B
Check
valve
specifi-
cation
: 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)
LFIA0217E
FRONT DISC BRAKE
BR-21
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FRONT DISC BRAKE PFP:41000
On-vehicle Inspection EFS003PN
PAD WEAR INSPECTION
G Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.
Components EFS003PO
Standard thickness : 11.88 mm (0.468 in)
Repair limit thickness : 1.0 mm (0.039 in)
BRA0010D
1. Upper sliding pin 2. Sliding pin boot 3. Torque member bolt
4. Torque member 5. Piston seal 6. Piston
7. Inner pad 8. Pad retainer 9. Outer pad
10. Piston boot 11. Union bolt 12. Copper washer
13. Sliding pin bolt 14. Bleed valve 15. Cylinder body
16. Cap 17. Brake hose 18. Lower sliding pin
WFIA0393E
BR-22
FRONT DISC BRAKE
Revision: August 2007 2004 QX56
WARNING:
Clean dust on cylinder body and brake pads with a vacuum dust collector to minimize the hazard of
airborne particles or other materials.
CAUTION:
G While removing cylinder body never depress brake pedal because piston will pop out.
G It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of cylinder body. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
G Do not damage piston boot.
G Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or if a soft
pedal occurs at very low mileage. Refer to BR-25, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad EFS003PP
REMOVAL
1. Remove wheel and tire using power tool.
2. Remove master cylinder reservoir cap.
3. Remove lower sliding pin bolt using power tool.
4. Suspend cylinder body with a wire and remove pads, shims and retainers from torque member.
INSTALLATION
1. Apply Molykote AS880N grease between brake pad plate and shim, then attach shims to brake pads.
Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" .
2. Attach pad retainer to torque member, then install brake pad and
shim assemblies.
CAUTION:
When attaching pad retainer, attach it firmly so that it is
flush with torque member, as shown.
3. Push pistons into cylinder body.
NOTE:
Using a disc brake piston tool (commercial service tool), etc.,
makes it easier to push in piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder
reservoir tank. Watch the level of the surface of reservoir tank.
4. Remove wire then swing cylinder body down over brake pad assemblies.
5. Install lower sliding pin bolt and tighten to specification. Refer to BR-21, "Components" .
6. Check brake for drag.
7. Inspect fluid level, then install master cylinder reservoir cap.
8. Install wheel and tire. Refer to WT-6, "Rotation" .
Removal and Installation of Brake Caliper and Disc Rotor EFS0062V
REMOVAL
1. Remove wheel and tire using power tool.
2. Drain brake fluid, as necessary. Refer to BR-10, "Drain and Refill" .
NOTE:
Do not remove union bolt unless removing cylinder body from vehicle.
3. Remove union bolt as necessary and torque member bolts, then remove cylinder body and torque mem-
ber assembly.
NOTE:
Position cylinder body aside using suitable wire, as necessary.
NOTE:
When servicing cylinder body, remove sliding pin bolts and cylinder body from torque member.
4. Remove torque member, as necessary.
5. Remove disc rotor.
PFIA0273E
FRONT DISC BRAKE
BR-23
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INSTALLATION
CAUTION:
G Refill with new brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" .
G Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install torque member and tighten to specification. Refer to BR-21, "Components" .
3. Install sliding pin bolts, if removed.
4. Install cylinder body, then tighten sliding pin bolts to the specified
torque. Refer to BR-21, "Components" .
CAUTION:
G When attaching cylinder body to the vehicle, wipe any oil
off knuckle spindle, washers and cylinder body attach-
ment surfaces.
G Do not reuse cylinder body torque member bolts.
5. Install brake hose to cylinder body, if removed, then tighten
union bolt to the specified torque. Refer to BR-21, "Compo-
nents" .
CAUTION:
G Do not reuse copper washers for union bolt.
G Attach brake hose to cylinder body together with union
bolt and washers.
6. Refill new brake fluid and bleed air. Refer to BR-11, "Bleeding Brake System" .
7. Install wheel and tire. Refer to WT-6, "Rotation" .
Disassembly and Assembly of Brake Caliper Assembly EFS003PR
DISASSEMBLY
1. Remove sliding pin bolt, and then remove the pad, shim, shim cover, and pad retainer from the torque
member.
2. Remove sliding pins and sliding pin boots from torque member.
3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
LFIA0209E
LFIA0214E
MAA0272D
BR-24
FRONT DISC BRAKE
Revision: August 2007 2004 QX56
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION:
Be careful not to damage cylinder body inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:
G Use new brake fluid for cleaning. Do not use mineral oils such as gasoline or kerosene.
G Check inside surface of cylinder body for score, rust, wear, damage or foreign materials. If any of
the above conditions are observed, replace cylinder body.
G Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the above con-
dition are observed.
CAUTION:
Piston sliding surface is plated, do not polish with emery paper even if rust or foreign materials are
stuck to sliding surface.
Sliding Pins, and Sliding Pin Boots
Check sliding pin and sliding pin boot for wear, damage, and cracks. If damage or deformation is present,
replace the affected part.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
ASSEMBLY
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply clean brake fluid to new piston seal and insert seal in to
groove on cylinder body.
CAUTION:
Do not reuse piston seal.
SFIA1301E
WFIA0210E
FRONT DISC BRAKE
BR-25
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2. Apply brake fluid to piston and piston boot, then install piston
boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder body inner wall from being
rubbed.
4. Install sliding pins and sliding pin boots to torque member.
CAUTION:
Trailing/upper sliding pin must be replaced at each service.
5. Install cylinder body. Tighten sliding pin bolt to the specified torque. Refer to BR-21, "Components" .
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any of them is detected, replace
applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheel hub at 2 or more positions.
2. Inspect runout using a dial gauge. (Measured at 10 mm (0.39 in)
inside the disc edge.)
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cations before measuring runout. Refer to FAX-5, "WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole.
4. If runout still out of specification, turn rotor with on-car brake
lathe.
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
WFIA0211E
Runout limit (on vehicle) : 0.04 mm (0.0016 in)
BRA0013D
Standard thickness : 26.0 mm (1.024 in)
Repair limit thickness : 24.5 mm (0.965 in)
Maximum uneven wear
(Measured at 8 positions)
: 0.015 mm (0.0006 in)
SBR020B
BR-26
FRONT DISC BRAKE
Revision: August 2007 2004 QX56
CAUTION:
Only perform this procedure 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/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool 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
BR-27
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REAR DISC BRAKE PFP:44000
On-vehicle Inspection EFS003PS
PAD WEAR INSPECTION
G Inspect the thickness of pad through cylinder body inspection
hole. Use a scale for inspection if necessary.
Components EFS003PT
WARNING:
Clean dust on cylinder body and brake pad with a vacuum dust collector to minimize the hazard of air-
borne particles or other materials.
Standard thickness : 12.13 mm (0.478 in)
Repair limit thickness : 1.0 mm (0.039 in)
BRA0010D
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Mounting bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Knuckle slide 12. Sliding sleeve boot
13. Sliding sleeve 14. Inner pad 15. Outer pad
WFIA0422E
BR-28
REAR DISC BRAKE
Revision: August 2007 2004 QX56
CAUTION:
G While removing cylinder body, never depress brake pedal because piston will pop out.
G It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of cylinder body assembly. In this case, hang cylinder body with a wire so as not to
stretch brake hose.
G Do not damage piston boot.
G Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer to BR-31, "BRAKE BURNISHING PROCEDURE" .
Removal and Installation of Brake Pad EFS003PU
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove mounting bolt from the top mount.
3. Swing cylinder body open, and remove pads.
INSTALLATION
1. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), makes it easier to push in the piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
2. Install pads to cylinder body.
3. Install top mounting bolt and tighten to specification.
4. Check brake for drag.
5. Install tires to the vehicle. Refer to WT-6, "Rotation"
Removal and Installation of Brake Caliper Assembly and Disc Rotor EFS003PV
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid as necessary. Refer to BR-10, "Drain and Refill" .
NOTE:
Do not remove union bolt unless removing cylinder body from vehicle.
3. Remove mounting bolts and cylinder body.
NOTE:
Position cylinder body aside using suitable wire, as necessary.
4. Remove disc rotor.
INSTALLATION
CAUTION:
G Refill with recommended brake fluid. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
G Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install cylinder body to the vehicle, and tighten mounting bolts to specification. Refer to BR-27, "Compo-
nents" .
CAUTION:
Before installing cylinder body to the vehicle, wipe off mounting surface of cylinder body.
LFIA0211E
REAR DISC BRAKE
BR-29
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3. Install brake hose to cylinder body and tighten union bolt to specification as necessary. Refer to BR-27,
"Components" .
CAUTION:
G Do not reuse copper washers.
G Securely attach brake hose to protrusion on cylinder body.
4. Refill with new brake fluid and bleed air as necessary. Refer to BR-11, "Bleeding Brake System" .
5. Install tires to the vehicle. Refer to WT-6, "Rotation"
Disassembly and Assembly of Brake Caliper Assembly EFS003PW
DISASSEMBLY
1. Remove pads from cylinder body.
2. Remove sliding sleeve and boot from cylinder body body.
3. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove piston and piston boot.
CAUTION:
Do not get your fingers caught in piston.
4. Using a flat-bladed screwdriver, remove piston seal from cylin-
der body.
CAUTION:
Be careful not to damage cylinder body inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:
G Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
G Check inside surface of cylinder body for score, rust wear, damage or foreign materials. If any of
the above conditions are observed, replace cylinder body.
G Minor damage from rust or foreign materials may be eliminated by polishing surface with a fine
emery paper. Replace cylinder body if necessary.
Torque Member
Check for wear, cracks, and damage. If damage or deformation is present, replace the affected part.
Piston
CAUTION:
G Piston sliding surface is plated, do not polish with emery paper even if rust of foreign materials
are stuck to sliding surface.
G Check piston for score, rust, wear, damage or presence of foreign materials. Replace if any of the
above conditions are observed.
Sliding Pin Bolts and Sliding Pin Boots
Make sure there is no wear, damage, or cracks in sliding sleeve and sliding sleeve boots, and if there are,
replace them.
BRD0041D
PFIA0269E
BR-30
REAR DISC BRAKE
Revision: August 2007 2004 QX56
ASSEMBLY
CAUTION:
Do not use NISSAN Rubber Grease (KRE00 00010, KRE00 00010 01) when assembling.
1. Apply clean brake fluid to new piston seal and insert in to
groove on cylinder body.
CAUTION:
Do not reuse piston seal.
2. Apply brake fluid to piston and to piston boot, then install piston
boot in to piston groove.
CAUTION:
Do not reuse piston boot.
3. Insert into cylinder body by hand and insert piston boot piston-side lip into piston groove.
CAUTION:
Press piston evenly and vary the pressing point to prevent cylinder body inner wall from being
rubbed.
4. Install sliding boots and sleeves to cylinder body.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is
detected, replace applicable part.
Runout Inspection
1. Using wheel nuts, install disc rotor to wheel hub. (2 or more positions.)
2. Inspect runout using a dial gauge. [Measured at 10 mm (0.39 in)
inside disk edge.]
NOTE:
Make sure that wheel bearing axial end play is within the specifi-
cation before measuring runout. Refer to RAX-5, "WHEEL
BEARING INSPECTION" .
3. If runout is outside the limit, find the minimum runout point by
shifting mounting positions of disc rotor and wheel hub by one
hole.
4. If runout still out of specification, turn rotor with on-car brake
lathe.
WFIA0210E
WFIA0211E
Runout limit (on vehicle) : 0.05 mm (0.0020 in)
BRA0013D
REAR DISC BRAKE
BR-31
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Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is
either at or below the wear limit, or exceeds maximum uneven wear,
replace disc rotor.
BRAKE BURNISHING PROCEDURE
Burnish brake contact surface according to the following procedure after refinishing or replacing rotors, after
replacing pads, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure 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/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust
brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds.
3. To cool 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.
Standard thickness : 14.0 mm (0.551 in)
Wear limit : 12.0 mm (0.472 in)
Maximum uneven wear
(measured at 8 positions)
: 0.015 mm (0.0006 in)
SBR020B
BR-32
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: August 2007 2004 QX56
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
General Specifications EFS003PX
Unit: mm (in)
Brake Pedal EFS003PY
Unit: mm (in)
Brake Booster EFS003PZ
Unit: mm (in)
Check Valve EFS003Q0
Unit: kPa (mmHg, inHg)
Front Disc Brake EFS003Q1
Unit: mm (in)
Front brake Brake model CLZ31VC
Rotor outer diameter thickness 320 26 (12.60 1.02)
Pad Length width thickness 111.0 73.5 9.5 (4.73 2.894 0.374)
Cylinder bore diameter 51 (2.01)
Rear brake Brake model AD14VE
Rotor outer diameter thickness 320 14 (12.60 0.55)
Pad Length width thickness 83.0 33.0 8.5 (3.268 1.299 0.335)
Cylinder bore diameter 48 (1.89)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
Diaphragm diameter 215 (8.46)
Recommended brake fluid
Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
Brake pedal height (from dash lower panel top surface) 182.3 192.3 (7.18 7.57)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb)
with engine running]
More than 90.3 (3.55)
Clearance between stopper rubber and the threaded end of stop
lamp switch
0.74 1.96 (0.029 0.077)
Pedal play 3 11 (0.12 0.43)
Input rod installation standard dimension 15.6 15.9 (0.614 0.626)
Vacuum leakage
[at vacuum of 66.7 ( 500, 19.69)]
Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Brake model CLZ31VC
Brake pad
Standard thickness (new) 11.88 (0.468)
Repair limit thickness 1.0 (0.039)
Disc rotor
Standard thickness (new) 26.0 (1.024)
Repair limit thickness 24.5 (0.965)
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.04 (0.0016)
SERVICE DATA AND SPECIFICATIONS (SDS)
BR-33
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Rear Disc Brake EFS003Q2
Unit: mm (in)
Brake model AD14VE
Brake pad
Standard thickness (new) 12.13 (0.478)
Repair limit thickness 1.0 (0.039)
Disc rotor
Standard thickness (new) 14.0 (0.551)
Repair limit thickness 12.0 (0.472)
Maximum uneven wear (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.05 (0.0020)
BR-34
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: August 2007 2004 QX56