Page 1
BRAKE SYSTEM
F BRAKES
A
B
SECTION BR
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Rest raint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .......................... ...................... 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
Inspection and Adjustment ....................................... 6
PLAY AND CLEARANCE BETWEEN BRAKE
PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED. ............. .......................................... 6
ADJUSTMENT ................... ................................... 7
Removal and Installation .......................................... 7
COMPONENT PARTS LOCATION ....................... 7
REMOVAL ............................................................. 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 8
BRAKE FLUID ............................................................ 9
Checking Brake Fluid Level ..................................... 9
Drain and Refill ......................................................... 9
Bleeding Brake System .......................................... 10
BRAKE PIPING AND HOSE .....................................11
Hydraulic Circuit ......................................................11
Front Brake Piping and Hose ..................................11
REMOVAL ............................................................11
INSTALLATION ....................................................11
Rear Brake Piping and Hose .................................. 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection After Installation .................................... 13
BRAKE MASTER CYLINDER .................................. 14
On-Board Inspection .............................................. 14
LEAK INSPECTION ............................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
CONTENTS
INSTALLATION ................................................... 14
Disassembly and Assembly ....................................15
COMPONENTS ..................... .............................. 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 15
BRAKE BOOSTER ................................................... 17
On-Vehicle Service ............ ....... ..............................17
OPERATING CHECK ............................... ....... ....17
AIRTIGHT CHECK ..............................................17
Removal and Installation ........................................ 17
COMPONENTS ..................... .............................. 17
REMOVAL ...........................................................17
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 18
VACUUM LINES ....................................................... 19
Removal and Installation ........................................ 19
Inspection ...............................................................19
VISUAL INSPECTION ......................................... 19
CHECK VALVE INSPECTION ............................. 20
FRONT DISC BRAKE ...............................................21
Components ........................................................... 21
On-Vehicle Inspection .................................. ...........22
PAD WEAR INSPECTION ...................................22
Removal and Installation of Brake Pad .................. 22
REMOVAL ...........................................................22
INSTALLATION ................................................... 23
Removal and Installation of Brake Caliper Assembly
REMOVAL ...........................................................23
INSTALLATION ................................................... 23
Disassembly and Assembly of Brake Caliper
Assembly ..................... ........................................... 24
DISASSEMBLY ................................................... 24
INSPECTION AFTER DISASSEMBLY ................24
DISC ROTOR INSPECTION ...............................25
ASSEMBLY ......................................................... 25
Brake Burnishing Procedure ................................... 26
REAR DISC BRAKE ................................................. 28
Component .................. ........................................... 28
On-Vehicle Inspection .................................. ...........29
BRAKE SYSTEM
...23
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Edition: 2004 September 2005 G35 Coupe
BR-1
Page 2
PAD WEAR INSPECTION ................................... 29
Removal and Installation of Brake pad ...................29
REMOVAL ........................................................... 29
INSTALLATION .................................................... 30
Removal and Installation of Brake Caliper Assembly
...30
REMOVAL ........................................................... 30
INSTALLATION .................................................... 30
Disassembly and Assembly of Brake Caliper
Assembly ................................................................31
DISASSEMBLY ................................................... 31
INSPECTION AFTER DISASSEMBLY ..... ....... ....31
DISC ROTOR INSPECTION ...............................32
ASSEMBLY ...................................................... ....32
Brake Burnishing Procedure ...................................33
SERVICE DATA AND SPECIFICATIONS (SDS) ......34
General Specifications ............................................34
Brake Pedal ............................................................34
Check Valve .............................. ..............................34
Brake Booster .........................................................34
Front Disc Brake .....................................................34
Rear Disc Brake ......................................................35
Edition: 2004 September 2005 G35 Coupe
BR-2
Page 3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
AFS002ST
A
The Supplemental Rest raint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used al ong
with a front seat belt, helps to redu ce th e risk or se verit y of i njury to the driv er and front passenge r for ce rtain
types of collision. This system includes seat belt switch inputs and dual st age 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 Manual.
WARNING:
● To avoid rendering the SRS inopera tive, whi ch could incr ease the risk of pe rsonal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, inc luding incorrect removal and installation of the SRS, can lead to per-
sonal injury ca use d by unintentional ac tiv atio n o f the system. For re mo va l of Spiral Cable and Ai r
Bag Module, see the SRS sec tion.
● Do not use electrical test equ ipment o n any circu it related to the SRS unless in structed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake System AFS002SU
● Recommended fluid is brake fluid “DOT 3”.
● Never reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas.
● To clean or wash all parts of mast er cylinder, disc brake caliper and wheel cylinder, use clean brake fluid.
● Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraul ic system.
● Use a flare nut wrench when removing a brake tube and use a
flare nut torque wrench when installing a brake tube.
● When instal ling brake piping, be sure to check torque.
● Before working, turn ignition switch OFF and disconnect con-
nectors of VDC/TCS/ABS control unit or the battery cable from
the negative terminal.
● Burnish the brake co ntact surfaces after refi nishing or rep lacing
drums or rotors, af ter rep lacin g pads or lini ngs, or if a soft p edal
occurs at very low mile age.
Refer to BR-26, "
Brake Burnishing Procedure" .
WARNING:
● Collect dust on brake parts with dust collector. Do not blow off the dust.
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Edition: 2004 September 2005 G35 Coupe
BR-3
Page 4
PREPARATION
PREPARATION PFP:00002 Commercial Service Tools AFS002SV
Tool name Description
1. Flare nut crowfoot
a:10 mm (0.39 in) (Other)
a:12 mm (0.47 in) (Between VDC
actuator and master cylinder)
2. Torque wrench
S-NT360
Installing brake piping
Power tool
Pin punch
Tip diameter: 4 mm (0.16 in) dia
Removing front/rear caliper assembly
and tire
PBIC0190E
Removing and installing reservoir tank
pin
ZZA0515D
Edition: 2004 September 2005 G35 Coupe
BR-4
Page 5
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting Chart AFS002SW
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
A
B
C
Reference page
Possible cause and
SUSPECT ED PARTS
Noise ××× ×× ×××
Symptom BRAKE
×: Applicable
Shake ×××××
Shimmy, Judder ЧЧЧЧЧЧЧЧ ××× ×
,BR-32
—
BR-25,BR-32
BR-25,BR-32
BR-25,BR-32
BR-25,BR-32
BR-22, BR-29
BR-22, BR-29
BR-22, BR-29
BR-25,BR-32
—
BR-25
D
E
NVH in PR section
NHV in RFD section
NVH in FAX, RAX and FSU, RSU section
NVH in WT section
NVH in WT section
NVH in RAX section
NVH in PS section
BR
G
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Pads - damaged
Pads - uneven wear
Shims damaged
Rotor imbalance
Rotor damage
Rotor runout
Rotor deformation
Rotor deflection
Rotor rust
Rotor thickness variation
Drum out of round
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
STEERING
×
×
×
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Edition: 2004 September 2005 G35 Coupe
BR-5
L
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Page 6
BRAKE PEDAL
BRAKE PEDAL P FP:4650 1 Inspection and Adjustment AFS002SX
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED.
1. Check brake pedal play.
2. Check brake pedal free height from dash lower panel.
3. Adjust the height referring to the following specifications.
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A Pedal play 3 - 1 1 mm (0.12 - 0.43 in)
Brake pedal free height (from dash
panel top surface)
Brake peda l depr essed heig ht (u nder a
force of 490 N (50 kg, 110 lb) with the
engine running)
Clearance between stopper rubber and the threaded
end of stop lamp switch and ASCD cancel switch.
SFIA2281E
M/T model 154 - 164 mm (6.0 6 - 6.46 i n)
A/T model 162 - 172 mm (6.38 - 6.77 in)
M/T model 90 mm (3.54 in) or more
A/T model 95 mm (3.74 in) or more
0.74 - 1.96 mm
(0.0291 - 0.0772 in)
Edition: 2004 September 2005 G35 Coupe
BR-6
Page 7
BRAKE PEDAL
ADJUSTMENT
1. Loosen stop lamp switch and ASCD cancel switch by rotating it
counterclockwise by 45°.
2. Loosen lock nut (A) on input rod, then rotate input rod to set
pedal to the specified heigh t, and tighten lock nut (A).
CAUTION:
Make sure that the threaded end of input rod stays inside
clevis.
Lock nut (A) :
Refer to BR-17, "
3. With th e pedal pulled a nd held by hand , press stop lam p swit ch
and ASCD cancel switch until its threaded end contacts stopper
rubber.
4. With the threaded end of stop lamp switch and ASCD cancel
switch contacting stopper rubber, rotate the switch clockwise by
45° to secure.
CAUTION:
Make sure that the clearance (C) between stopper rubber
and threaded end of stop lamp switch and ASCD cancel
switch is within the standard.
5. Check the pedal play.
CAUTION:
Make sure that stop lamps go off when pedal is released.
6. Start engine to check brake pedal depressed height.
COMPONENTS" .
A
B
C
D
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BR
G
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Removal and Installation AFS002SY
COMPONENT PARTS LOCATION
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Edition: 2004 September 2005 G35 Coupe
BR-7
Page 8
BRAKE PEDAL
REMOVAL
1. Remove the inst rument lower driver panel. Refer to IP-13, "(J)
Instrument Lower Driver Panel" .
2. Remove stop lamp switch and ASCD cancel switch from pedal
assembly.
3. Remove snap pin and clevis pin from clevis of brake booster.
4. Remove mountin g nut s and bo lt fr om brack et, and remo ve pedal
assembly from vehicle.
INSPECTION AFTER REMOVAL
● Check brake pedal upper rivet for deform a tio n.
● Make sure that the lapping length of sub-bracket and slide plate
is at least 5. 5 mm (0.22 in).
● Check brake pedal for bend, damage, an d cracks on the welded
parts.
● Replace brake pedal assembly if any non-standard condition is
detected.
SFIA0159E
● Check clevis pin and plastic stop per for damage and d eforma-
tion. Replace clevis pin if there are.
INSTALLATION
Installation is in the reverse order of the removal.
● After installing brake pedal assembl y to vehicle, adjust brake pedal. Refer to BR-7, "ADJUSTMENT" .
SFIA2824E
SBR997
Edition: 2004 September 2005 G35 Coupe
BR-8
Page 9
BRAKE FLUID
BRAKE FLUID PFP:KN100
Checking Brake Fluid Level AFS002SZ
● Check fluid leve l in res erv oir t ank . It sho uld b e bet ween Ma x and
Min lines on reservoir tank.
● If fluid level is extremely low, check brake system for leaks.
● Release parking brake lever or pedal, and then see if brake
warning lamp goes off. If not, check brake syst em for leaks.
SFIA2484E
Drain and Refill AFS002T0
CAUTION:
● Carefully monitor brake fluid level in reservoir tank during draining operation.
● Refill with new brake fluid “DOT3”.
● Never reuse drained brake fluid.
● Do not let brake fluid splash on painted surfaces of body. This might damage the paint, when
splashing it on the surfaces, immediately wipe off the m with cloth and wash it away with water.
1. Turn ignition switch OFF and remove the batte ry cable from the negative terminal.
2. Connect a vinyl tube to bleed valve.
3. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
A
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4. Make sure there is n o fore ign ma terial in th e res ervoi r tank, and
refill with new brake fluid.
5. Rest foo t on brake pedal. Loosen bleed va lve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal.
Repeat this pr ocess a few time s, then pause to add ne w brake
fluid to master cylinder. Continue until new brake fluid flows out.
Bleed Air. Refer toBR-10, "
Bleeding Brake System" .
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BRA0006D
Edition: 2004 September 2005 G35 Coupe
BR-9
Page 10
BRAKE FLUID
Bleeding Brake System AFS002T1
CAUTION:
● Carefully monitor brake fluid level in reservoir tank
during bleeding operation.
● Fill reservoir with new brake fluid “DOT 3”. Make sure it
is at least half way at all times while bleeding air out of system.
● Place a container un der maste r cyl inde r to av oid spill age of
brake fluid.
● Turn ignition switch OFF and disconnect VDC actuator
connectors or the battery cable from negative terminal.
SBR995
● Bleed air in the following order. Right rear brake → Left
front brake → Left rear brak e → Right front brake
1. Connect a transparent vinyl tube to bleed valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open bleed valv e to release air.
4. Close bleed valve.
5. Release brake pedal slowly.
6. Repeat steps 2 through 5 until clear brake fluid comes out
of bleed valve.
SBR419C
Edition: 2004 September 2005 G35 Coupe
BR-10
Page 11
BRAKE PIPING AND HOSE
BRAKE PIPING AND HOSE PFP:46210
Hydraulic Circuit AFS002T2
A
B
C
D
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BR
SFIA2691E
CAUTION:
● All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
● Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.
● The brake tubes and hoses are an important safety parts. If a brake fluid leak is detected, always
disassemble the parts. Replace ap plicable part with a new one, if necessary.
● Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted surfaces of body, immediately wipe it off with cloth and then wash it away
with water.
● Do not bend or twist brake hose sharply, or strongly pull it.
● When removing c omponents, cover br ake line con nections so tha t no dirt, dus t, or other forei gn
matter gets in.
● Refill with new brake fluid “ DOT 3 ”.
● Do not reuse drained brake fluid.
Front Brake Piping and Hose AFS002T3
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose. Remove union bolt, and remove brake
hose from caliper asse m bly.
3. Remove lock plate.
4. Remove mounting nuts, and remove brake hose from vehicle.
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INSTALLATION
1. Assemble union bolt and copper washers to brake hose.
Edition: 2004 September 2005 G35 Coupe
BR-11
Page 12
BRAKE PIPING AND HOSE
2. Position the metal fitting of brake hose by aligning with the protrusion on the caliper assembly, and tighten union bolt to the
specified torque.
CAUTION:
● Do not reuse cop pe r was her.
● Refill with new brake fluid “DOT3”.
● Never reuse drained brake fluid.
SFIA2290E
3. Connect brake hose to brake tube on vehicle, and temporarily tighten flare nut by hand until as much as
possible. Fix it with lock plate, and tighten flare nut to the specified torque with a flare nut torque wrench.
4. Install brake hose to vehicle, and tighten mounting nuts to the specified torque.
5. After the wo rk, bleed air. Refer to BR-10, "
Bleeding Brake System" .
Rear Brake Piping and Hose AFS002T4
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt, and then remove brake hose from caliper
assembly.
4. Remove lock plate, and remove br ake hose from vehi cle.
INSTALLATION
1. Assemble union bolt and copper washers to brake hose.
2. Position the L-shape metal fitting of the brake hose to the brake
caliper assembly positioning hole, and then tighten union bolt to
the specified torque.
CAUTION:
● Do not reuse cop pe r was her.
● Refill with new brake fluid “DOT3”.
● Never reuse drained brake fluid.
3. Connect brake hose to brake tube on the vehicle, and temporarily tighten flare nut by hand as much as possib le. Sec ure it to
bracket with lock plate, and tighten flare nut to the specified
torque with a flare nut torque wrench.
4. After the wo rk, bleed air. Refer to BR-10, "
Bleeding Brake System" .
SFIA2178E
SFIA2302E
SFIA2049E
Edition: 2004 September 2005 G35 Coupe
BR-12
Page 13
BRAKE PIPING AND HOSE
Inspection After Installation AFS002T5
CAUTION:
If leak is detected at the connections, retighten it or replace the damaged part.
1. Check brake hose, tube, and connec tions for fluid leaks, damage , twist, deformation, contact with other
parts, and loose connections.
2. While depressing pedal under a force of 785 N (80 kg, 177 lb) with the engine running for approximately 5
seconds, check for fluid leak from each part.
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Edition: 2004 September 2005 G35 Coupe
BR-13
Page 14
BRAKE MASTER CYLINDER
BRAKE MASTER CYLINDER PFP:46010 On-Board Inspection AFS002T6
LEAK INSPECTION
● Check for leaking in a master cylinder installation surface, a reservoir tank installation surface, and brake
tube connections.
Removal and Installation AFS002T7
CAUTION:
● Be careful not to splash brake fluid on painted area s; it may cause paint damage. If br ake fluid is
splashed on painted areas, immediately wipe it off with cloth and wash it away with water.
● Do not operate with primary piston when removing and installing.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Remove harnes s connector for brake fluid level swi tch.
3. Using a flare nut wrench, remove brake tube from master cylinder.
4. Remove mounti ng nuts, and remove master cylind er assembly from vehicle. Refe r to BR-17, "
and Installation" .
INSTALLATION
CAUTION:
● Refill with new brake fluid “DOT3”.
● Never reuse drained brake fluid.
1. Install master cylinder to brake booster assembly, and tighten mounting nuts to the specified torque.
CAUTION:
● Check if the lot of primary piston has dust or scratch.
● Do not damage and stain rod of primary piston.
● Do not reuse O-ring.
● Apply silicon grease or brake fluid for O-ring and primary piston.
Removal
● Apply silicon grease to the master cylinder insertion of
brake booster.
2. Install brake tube to master cylinder, and temporarily tighten the flare nuts on the brake tube to master cylinder by hand.
3. Using a flare nut torque wrench, tighten flare nut on the brake tube to the specified torque.
4. Install harness connector of brake fluid level switch.
5. Refill new brak e flu id an d ble ed air. Refer to BR-10, "
Bleeding Br ake System" .
SFIA2825E
Edition: 2004 September 2005 G35 Coupe
BR-14
Page 15
BRAKE MASTER CYLINDER
Disassembly and Assembly AFS002T8
COMPONENTS
A
B
C
D
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BR
1. Reservoir tank 2. Reservoir cap 3. Oil filter
4. Grommet 5. Brake fluid level switch connector 6. Pin
7. Cylinder body 8. O-ring
DISASSEMBLY
CAUTION:
● Master cylinder cannot be disassembled.
● Remove the reservoir tank only when absolutely necessary.
1. Clamp flange of cy linder body in vise as shown in th e figure.
CAUTION:
● Using copper plate or cloth to cover flange for securing
2. Using a pin-pu nch [commer cial se rvice tool: diameter a pprox. 4
3. Remove master cylind er assembly from vise.
4. Remove reservoir tank and grommet from cylinder body.
vise.
● When securing master cylinder assembly in a vise, be
sure not to over tighten.
● Be sure to fix the flang e part with the installation side of
cylinder body brake tube up.
mm (0.16 in)], remove pin form reservoir tank.
SFIA2692E
BRA0558D
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BRA0559D
ASSEMBLY
CAUTION:
● Do not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
Edition: 2004 September 2005 G35 Coupe
BR-15
Page 16
BRAKE MASTER CYLINDER
● Do not drop parts. If a part is dr opped, do not use it.
1. Apply brake fluid to a grommet, and place it into master cylinder to install.
CAUTION:
Do not reuse grommet.
2. Install reservoir tank to master cylinder.
CAUTION:
● Do not reus e reservoir tank and reservoir tank mounting
pin.
● Pay attention to the orientation of reservoir tank.
3. Secure flange of cylinder body as shown in the figure.
CAUTION:
● Using copper plate or cloth to cover flange when secur-
ing in a vise.
● When securing master cylinder assembly in a vise, be
sure not to over tighten.
● Be sure to fix the fl ange part with the brake tub e installa-
tion side of cylinder body up.
BRA0568D
4. Using a pin punch [commercial service tool: diameter approx. 4
mm (0.16 in)], ins ert the rese rvoir tank moun ting pin i nto th e pi n
hole so that the attachment side and the opposite side are identical.
BRA0558D
BRA0559D
Edition: 2004 September 2005 G35 Coupe
BR-16
Page 17
BRAKE BOOSTER
BRAKE BOOSTER PFP:47200
On-Vehicle Service AFS002T9
OPERATING CHECK
With the engine stopped, change the vacuum to the atmospheric
pressure by dep ressing brake pedal several tim es. Then with brake
pedal fully depressed, start engine and when the vacuum pressure
reaches the stand ard, make s ure that the clearance bet ween brake
pedal and floor panel decreases.
CAUTION:
Depressing pedal interval is approximately 5 seconds.
A
B
C
D
AIRTIGHT CHECK
● Run engine at i dle for approxim ately 1 minute , and stop it after
applying vacuum to booster. Depress brake pedal normally to
change the vacuum to the atmospheric pressure. Make sure
that distance between brake pedal and floor panel gradually
increases.
● 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.
Removal and Installation AFS002TA
COMPONENTS
BRA0037D
SBR365AA
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1. Reservoir tank 2. Cylinder body 3. Gasket
4. Brake pedal 5. Lock nut 6. Brake booster
REMOVAL
CAUTION:
● Be careful not to splash brake fluid on painted areas such as body. It may cause paint damage. If
brake fluid is spla shed on painted surfaces of body, wipe it off with cloth immediat ely and then,
wash it away with water.
● Be careful not to deform or bend brake piping while removing and installing brake booster.
Edition: 2004 September 2005 G35 Coupe
BR-17
M
Page 18
BRAKE BOOSTER
● Replace clevis pin if it is damaged.
● 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.
● Be sure to install check valve in the correct orientation.
1. Remove vacuum hose from brake booster.
2. Remove master cylinder. Refe r to BR-14, "
3. Remove snap pin and clevis pin on the clevis of the brake booster, and remove input rod from brake
pedal. Refer to BR-7, "
COMPONENT PARTS LOCATION" .
4. Remove brake pedal mounting nuts on pedal br acket.
5. 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 r od length.
Standard dimension when vacuuming
–66.7 kPa (–500 mmHg, –19.69 inHg)
: 30.5 mm (1.20 in)
Removal and I nstallation" .
INSTALLATION
1. Loosen lock nut to adjust input rod leng th so that the length B
(shown in the figure) satisfies the specified value.
Length “B” : 125 mm (4.92 in)
2. After adjusting length “B”, temporarily tighten lock nut to install
brake booster assembly to dash panel. At this time, make sure
to install a gasket between booster assembly and dash panel.
3. Connect brak e pe da l to cle vi s o f inp ut r od w it h th e c le vi s pi n and
snap pin.
4. Install brake pedal bracket mounting nuts and tighten them to
the specified torque.
5. Install vacuum hos e in to bra ke boos te r. Refer to BR-19, "
6. Install master cylinder to booster assembly. Refer to BR-14, "
7. Adjust the height and play of brake pedal. Refer to BR-7, "
8. Tighten lock nut of input rod to th e specified t orque.
9. Bleed air. Refer to BR-10, "
Bleeding Brake System" .
SFIA2146E
SGIA0060E
Removal and Installation" .
Removal and I nstallation" .
ADJUSTMENT" .
Edition: 2004 September 2005 G35 Coupe
BR-18
Page 19
VACUUM LINES
VACUUM LINES PFP:41920
Removal and Installation AFS002TB
A
B
C
D
E
BR
SFIA2693E
1. Engine direction indicator stamp
(build i n check valve)
4. Vacuum piping 5. Vacuum hose 6. For brake booster
7. Orifice mark
2. For intake manifold 3. Clamp
CAUTION:
● Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer
to the stamp or label to confirm correct installation. Brake booster will not operate normally if
hose is installed in the wrong direction.
● Insert vacuum hose for at least 24 mm (0.94 in).
● Never use lubricating oil during assembly.
Inspection AFS002TC
VISUAL INSPECTION
Check for improper assembly, damage and aging.
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SBR225B
Edition: 2004 September 2005 G35 Coupe
BR-19
Page 20
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.
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
VACUUM LINES
SFIA0210E
Edition: 2004 September 2005 G35 Coupe
BR-20
Page 21
FRONT DISC BRAKE
FRONT DISC BRAKE PFP:41000
Components AFS002TD
A
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C
D
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BR
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SFIA2827E
1. Sl idi ng pi n 2. Sliding pin boot 3. Washer
4. Torque member 5. Torque member mounting bolt 6. inner shim
7. I nner pad 8. Pad retainer 9. Outer pad
10. Outer shim 11. Out er shi m co ver 12. Union bolt
13. Copper washer 14. Bleed valve 15. Cylinder body
16. Piston seal 17. Piston 18. Piston boot
19. Sliding pin bolt 20. Cap 21. Bush
CAUTION:
● Clean dust on caliper and br ake pad with a vacuum dust co llector. Do not blow with compressed
air.
● While removing cylinder body, do not depress brake pedal because piston will pop out.
● It is not necessary to remove torque member mo unting bolts on torque member an d brake hose
except for disassembly or replacement of caliper assembly. In this case, hang cylinder body with a
wire so that brake hose is not under tension.
● Do not damage piston boot.
● Always replace shim and shim covers as a set when replacing brake pads.
● Keep rotor clean, from brake fluid.
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Edition: 2004 September 2005 G35 Coupe
BR-21
Page 22
FRONT DISC BRAKE
On-Vehicle Inspection AFS002TE
PAD WEAR INSPECTION
● Check pad thickness from check hole on cylinder body.
Standard thickness : 11.0 mm (0.433 in)
Replace limit thickness : 2.0 mm (0.079 in)
Removal and Installation of Brake Pad AFS002TF
REMOVAL
WARNING:
Clean brake pads with a vacuum dust collector to minimize a hazard of airborne particles or other
materials.
CAUTION:
● While removing pad assembles, do not depress brake pedal because piston will pop out.
● Be careful not to damage piston bo ot or get oil on disc rotor. Always replace shims in replacing
pads.
● If shims are rusted or show peeling of rubber coat, replace them with new shims.
● It is not necessary to remove torque member mounting bolt ex cept for disassembly or replace-
ment of caliper asse mb ly. In this case, suspend c yli nde r body w ith wi re s o as no t to st retc h bra ke
hose.
● Carefully monitor brake fluid level becaus e brake fluid wi ll return to reservoir when pushi ng back
piston.
● Burnish the brake pads (or linings) and disc rotor mutually contacting 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-26, "
1. Remove tires from vehicle with a power tool.
2. Remove lower sliding pin bolt.
Brake Burnishing Procedure" .
MAA0439D
SBR433D
3. Hang cylinder body with a wi re, and remove pads, shims and
pad retainers from torque member.
CAUTION:
● Do not damage piston boot.
● When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.
● Do not damage piston boot.
● Keep rotor clean, free from brake fluid.
SBR556E
Edition: 2004 September 2005 G35 Coupe
BR-22
Page 23
FRONT DISC BRAKE
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) or equivalent to the outer shim
cover sides of outer shim. Install inner shim to inn er pad, and
outer shim and outer shim cover to ou ter pad.
2. Install pad retainers and pad assemblies to torque member.
CAUTION:
Inner pad and outer pad have pad-return mechanism on
upper side of pad retainer. When installing pad to torque
member, be sure to install pad return lever to pad wear sensor securely.
3. Install cyli nder body to tor que member.
CAUTION:
When replacing pads with new ones, press in piston until pads can be installed. In this case, carefully monitor brake fl uid level in reservoir tank because brake fluid will return to ma ster cylinder
reservoir tank.
4. Install lower sliding pin bo lt, and tighten it to the specif ied torque. Refer to BR-21, "
5. Secure disc rotor with wheel nu ts. Depress brake pedal a few times until it ge ts a responsive touch.
6. Check brake for drag.
7. Install tire to the vehicle.
Components" .
SBR557E
A
B
C
D
E
BR
Removal and Installation of Brake Caliper Assembly AFS002TG
REMOVAL
1. Remove tire from vehicle with a power tool.
2. Drain brake fluid gradually from bleed valve while depressing brake pedal. Refer to BR-9, "
Refill" .
3. Remove union bolt, and then remove brake hose from caliper
assembly.
4. Remove torque member mounting bolts from torque member,
and remove cali per assembly from vehicle with a pow er tool.
5. Remove disc rotor.
CAUTION:
Put matching marks on both disc rotor and wheel hub when
removing disc rotor.
INSTALLATION
1. Install disc rotor.
CAUTION:
Align the matching marks of d isc rotor and whe el hub, whic h were marke d at the time of removal
when reusing disc rotor.
2. Install calip er assembly to vehicle, and tighten mou nting bolts to the specified torque. Refer to BR-21,
"Components" .
CAUTION:
Before installing torque member to vehicle, wipe oil and grease on washer seats on steering
knuckle and mounting surface of torque member.
3. Install a projection of brake hose metal fitting by aligning with protrusions on cylinder body, and tighten
union bolt to the specified torque. Refer to BR-11, "
CAUTION:
● Do not reuse copper washers for union bolts.
● Assemble brake hose securely on caliper assembly.
4. After in s tallin g c a lip er as se m bly, refill with new b rak e fluid and bleed air. Refer to BR-10, "
System" .
5. Install tire s to vehicle.
Hydraulic Circuit" .
Drain and
Bleeding Brake
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Edition: 2004 September 2005 G35 Coupe
BR-23
Page 24
FRONT DISC BRAKE
Disassembly and Assembly of Brake Caliper Assembly AFS002TH
NOTE:
Do not remove to rque member, brake pads, shims, shim cove rs and pad retainers, when disas sembling or
assembling cylinder body.
DISASSEMBLY
1. Remove caliper assembly from vehicle. Refer to BR-23,
"REMOVAL" .
2. Remove sliding pin bolts from cylinder body, and remove pads,
shims, shim cover and pad retainers from torque member.
CAUTION:
When removing pad retainer from torque member, lift the
pad retainer in the direction shown by arro w (shown in the
figure) so as not to deform it.
SBR556E
3. Remove sliding pins and sliding pin boots fr om torque member.
4. Place a wood en block as shown in the figu re, and bl ow air from
union bolt mo unting hole to r emove pistons and piston boots.
5. Using a flat-bladed screwdriver, remove piston seals from cylinder body.
CAUTION:
Be careful not to damage the inner wall of cylinder.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.
● Check the inner wall of cylinder for corrosion, wear, and damage. If a malfunction is detected, replace cyl-
inder body.
● Minor flaws caused by corrosion or a foreign material can be removed by polishing a surface of the inner
wall with a fine sandpaper. Replace cylinder body, if a malfunction is detected.
To rque Member
Check for wear, cracks, and damage. If a malfunction is detected, replace applicable part.
BRB0032D
SFIA0141E
Piston
CAUTION:
The piston sliding surface is plat ed . Do not polish with san dpaper.
Check piston sur face for corrosion, wear, and damage. If a malfunction is detected, replace applicable part.
Edition: 2004 September 2005 G35 Coupe
BR-24
Page 25
FRONT DISC BRAKE
Sliding Pin, Slid in g Pin Bolt, and Sliding Pin Boot
Check sliding pi ns and sliding pin boots fo r wear, damage, and cracks. If a malfunc tion is detected, repl ace
applicable part.
A
DISC ROTOR INSPECTION
Visual Inspection
Check surfaces of disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace applicable part.
Runout Inspection
1. Using wheel nuts, secure disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check runout .
Measurement
point
: At a point 10.0 mm (0.394 in) from
outer edge of disc
Runout limit : 0.035 mm (0.0014 in) or less
CAUTION:
Before measuring, make sur e that ax le end play is 0 mm .
3. If runout is outside limit, find the minimum runout point by shifting the mounting positions of disc rotor and wheel hub by one
hole.
SBR019B
Thickness Inspection
1. Using a micrometer, check thickness of disc rotor. If thickness is
outside standard, replace di sc rotor.
Standard thickness : 28.0 mm (1.10 in)
Repair limit thickness : 26.0 mm (1.02 in)
Maximum uneven wear
(measured at 8 positions)
: 0.015 mm (0,0006 in)
or less
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2. If runout is still out of specification, grind rotor with on-car brake
lathe (″MAD, DL-8700″, ″AMMCO 700 and 705″″or equivalent)
until runout becomes within the specified limit.
ASSEMBLY
CAUTION:
Do not use Nissan Rubber Grease (KRE00 00010, KRE00 00010 01) during assembly.
1. Apply rubber grease to piston seals and install them to cylinder
body.
CAUTION:
Do not reuse piston seals.
SBR020B
SFIA2419E
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Edition: 2004 September 2005 G35 Coupe
BR-25
Page 26
FRONT DISC BRAKE
2. Apply rubber greas e to piston boots. Cover the piston end with
piston boot, and in stall cylinder-side lip on pis ton boot properly
into groove on cylinder bo dy.
CAUTION:
Do not reuse piston boot.
3. Apply brake fluid to piston, and press piston into cylinder body
by hand to assemble piston-side lip on piston boot properly into
a groove on piston.
CAUTION:
Press piston evenly and change pressing point to prevent
inner wall of cylinder from being rubbed.
4. Install s liding pins and sliding pin boots to the torque member.
SFIA0155E
5. Install the torq ue mem ber to th e steer ing kn uckl e and tigh ten the
mounting bolts to the specified torque. Refer to BR-21, "
Compo-
nents" .
CAUTION:
Before installing torque member to veh icle, wipe off oil a nd
grease on the washer seats on steering knuckle and the
mounting surface of the torque member.
6. Install pad retainers to torque member.
7. After assembling shims and shim covers to pad, install it to
torque member.
CAUTION:
Inner pad and outer pad have pad-return me chanism on the upper side o f the pad retainer. When
installing pad, be sure to install pad return lever to pad wear sensor securely as shown in the figure.
8. Install cylinder body, and tighten sliding pin bolt to the specified torque. Refer to BR-21, "
Components" .
9. Position a projection of brake hose metal fitting by aligning with protrusions on cylinder body and tighten
union bolt to specified torque. Refer to BR-11, "
Hydraulic Circuit" .
CAUTION:
● Assemb le brak e hos e secure ly to cyl inde r body.
● Do not reuse copper washer for union bolts.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
SBR574
SBR557E
Brake Burnishing Procedure AFS002TI
Burnish the brake pad (or lining) and disc rotor mutually contacting surfaces of disc rotor according to following
procedure aft e r ref in i shin g o r rep l aci n g dr ums o r r otor s , af ter re pl ac in g pa ds or l ini ng s, o r if a so ft pe da l o cc urs
at very low mileage.
CAUTION:
● Be careful of vehicle speed because brake does not operate easily until pad and disc rotor are
securely fitted.
● Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive vehicle on straight, flat road.
2. Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until th e vehicle stops.
Edition: 2004 September 2005 G35 Coupe
BR-26
Page 27
FRONT DISC BRAKE
3. Drive without depressing brake for a few minutes to cool brake.
4. Repeat steps 1 to 3 until pad and disc rotor are securely fitted.
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Edition: 2004 September 2005 G35 Coupe
BR-27
Page 28
REAR DISC BRAKE
REAR DISC BRAKE PFP:44000 Component AFS002TP
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 1 1. Retaining ring 12. Inner shim cover
13. Inner shim 14. Inner pad 15. Pad retainer
16. Outer pad 1 7. Outer shim 18. Slide pin boot
19. Torque member bolt 20. Bushing 21. T orque member
SFIA2839E
CAUTION:
● Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with com-
pressed air.
● While removing cylinder body, never depress brake pedal because the piston will pop out.
● It is not necessary to remove mounting bolts on the torque member and brake hose except for dis-
assembly or repl acem ent of ca liper asse mbly. In this case, hang cylind er bo dy wi th a wire so tha t
brake hose is not under tension.
● Do not damage piston boot.
● Always replace shims and shim covers as a set when replacing brake pads.
● Keep rotor clean, free from brake fluid.
Edition: 2004 September 2005 G35 Coupe
BR-28
Page 29
REAR DISC BRAKE
On-Vehicle Inspection AFS002TQ
PAD WEAR INSPECTION
● Check pad thickness from inspection hole on cylinder body.
A
Standard thickness : 8.5 mm (0.335 in)
Repair limit thickness : 2.0 mm (0.079 in)
Removal and Installation of Brake pad AFS002TR
REMOVAL
CAUTION:
● Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or
other materials.
● While removing pad assemblies, do not depress brake pedal, otherwise piston will pop out.
● Be careful not to damage pis ton boot or get oil on rotor, Always replace shims when replacing
pads.
● If shims are rusted or show peeling of rubber coat, replace them with new shims.
● It is not neces sary to remove connecting bolt except for disassem bly or replacement of cali per
assembly. In this case, suspend cylinder body with wire so as not to stretch brake hose.
● Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back
piston.
● Burnish the brake pads (or lining s) and disc rotors m utually contacting surfac es after refinishi ng
or replacing drums or rotor, after replacing pads or linings, or if a soft pedal occurs at very low
mileage. Refer to BR-33, "
1. Remove master cylinder reservoir cap.
2. Remove tire.
3. Remove lower sliding pin bolt.
Brake Burnishing Procedure" .
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4. Hang cylinder body with a wire, and remove pads, shims and
pad retainers from torque member.
CAUTION:
● Do not damage piston boot.
● When removing pad retainer from torque member, lift pad
retainer in the direction shown by arrow (shown in the
figure) so as not to deform it.
● Do not damage piston boot.
● Keep rotor clean, free from brake fluid.
SBR556E
Edition: 2004 September 2005 G35 Coupe
BR-29
L
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REAR DISC BRAKE
INSTALLATION
1. Apply brake grease to the back of pad and both sides of shim, and install inner shim and i nner shim cover
to inner pad, and outer shim and outer shim cov er to ou ter pad.
2. Install pad retainers and pad assembles to torque member.
3. Install cylinder body to torque member.
CAUTION:
When replacing pads with new ones, press in the piston until pads can be installed. In this case,
carefully monitor the brake fluid level in the reservoir tank because brake fluid will return to reservoir tank of master cylinder.
4. Insert lower sliding pin bolt to tighten to the specified torque. Refer to BR-28, "
5. Secure disc rotor with wheel nuts. Depress brake pedal a few times until it gets a respo nsive touch.
6. Check brake for drag.
7. Install tire to the vehicle.
Component" .
Removal and Installation of Brake Caliper Assembly AFS002TS
REMOVAL
1. Remove tire from vehicle with a power tool.
2. Drain brake fluid gradually from bleed valve while depressing
brake pedal.
3. Remove union bolt, and then remove brake hose from caliper
assembly.
4. Remove torque member fixing bolt from torque member, and
remove caliper assembly from vehicle with a power tool.
5. Remove disc rotor.
CAUTION:
Put matching mark on both disc rotor a nd wheel hub when
removing disc rotor.
SFIA0143E
INSTALLATION
1. Install disc rotor.
CAUTION:
Align the matching marks o f disc rotor and wh eel hub, whic h were marke d at the time of rem oval
when reusing disc rotor.
2. Install caliper assembly to vehicle, and tighten torque member fixing bolts to the specified torque. Refer to
BR-28, "
CAUTION:
Before installing caliper a ssem bly to vehic le, w ipe oi l and g rease on the w ash er sea ts on the axle
assembly and mounting surface of calip er ass em bly.
3. Install brake hose to caliper assembly and tighten union bolt to the specified torque. Refer to BR-28,
"Component" .
CAUTION:
● Do not reuse copper washers for union bolts.
● Assemble brake hose securely to the protrusion on caliper assembly.
4. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-10, "
System" .
5. Install tire to vehicle.
Component" .
Bleeding Brake
Edition: 2004 September 2005 G35 Coupe
BR-30
Page 31
REAR DISC BRAKE
Disassembly and Assembly of Brake Caliper Assembly AFS002TT
DISASSEMBLY
1. Remove caliper assembly from vehicle.
2. Remove sliding pin bo lt s and cyl ind er body from tor que mem ber.
Then remove pads, s hims, and shim cover s from torque member , and remove p ad retainers from cylinder body.
3. Remove sliding pin boot from torque member.
4. Using a flat-bladed screwdriver as shown in the figure, remove
retaining ring from torque member.
SBR028A
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5. Place a wooden block as shown in the figure, and blow air from
union bolt moun ting hole to remove piston and piston boots.
6. Remove piston seal with a flat-bladed screw driver.
CAUTION:
Be careful not damage cylinder inner wall.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. N ever use mineral oils such as gasoline or ker osene.
● Check the inn er w all o f cy lind er for corros ion, wear, and damage . I f a fa ilure is d etect ed, re place cyli nd er
body.
● Minor flaws caused by corrosion or fore ign material can b e removed by polis hing the surface with a fine
sandpaper. Replace cylinder body, if malfunction is detected.
BRD0041D
SFIA0999E
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Torque Member
Check for wear, cracks, and damage. If a malfunction is detected, replace applicable part.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check the pisto n surface for corrosion, wea r, and damage. If a malfu nction is detected, replace applicable
part.
Sliding Pin Bolt and Sliding Pin Boot
Check sliding pin bolts and sliding pi n bo ot for w ea r, dama ge , an d crac ks . If a mal fun ct io n is det ec ted , r ep lace
applicable part.
Edition: 2004 September 2005 G35 Coupe
BR-31
Page 32
REAR DISC BRAKE
DISC ROTOR INSPECTION
Visual Inspection
Check the surface of disc rotor for uneven wear, cracks, and serious damage. If a malfunction is detected,
replace applicable part.
Runout Inspection
1. Using wheel nuts, fix disc rotor to wheels hub. (2 or more positions)
2. Using a dial indicator, check the runout.
Measurement point:
At a point 10 mm (0.39 in) from the outer edge
of disc.
Runout limit:
0.055 mm (0.0022 in) or less
CAUTION:
Before measuring, make sure that the axle end play is 0.05
mm (0.002in) or less.
3. If the runo ut is ou t side the limi t, fi nd th e min imum runo ut p oint by
shifting th e mounting positions of disc rotor and wheel hub by one hole.
Thickness Inspection
1. Using a micrometer, check the thickness of disc rotor. If the
thickness is outside the standard, replace disc rotor.
BRA0013D
Standard thickn ess : 16.0 mm (0.6 30 in)
Repair limit thickness : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions):
0.015 mm (0.0006 in) or less
2. If runout is still ou t of specific ation, gr ind roto r with on-car br ake
lathe (″MAD, DL-8700″, ″AMMCO 700 and 705″″or equivalent)
until runout becomes within the specified limit.
ASSEMBLY
CAUTION:
When assembling, do not use NISSAN rubber grease (KRE00 00010, KRE00 00010 01).
1. Apply rubber grease to new piston seals, and install them to
groove on cylinder body.
CAUTION:
Do not reus e piston seal.
SBR020B
SFIA1785E
Edition: 2004 September 2005 G35 Coupe
BR-32
Page 33
REAR DISC BRAKE
2. Apply rubb er grease to piston boots. Cover piston end with piston boot, and i nstall cylinde r- si de li p on t he pi ston bo ots properly
into the groove on the cylinder body.
CAUTION:
Do not reuse piston boot.
3. Press piston into c y lin de r b od y by hand to assemb le p is t on -si de
lip on the piston boot properly into the groove on the piston.
CAUTION:
Press piston evenly an d change the pressing point to prevent the inner wall of cylinder from being rubbed.
4. Fix piston boot w ith retaining ring.
CAUTION:
● Make sure that boot i s se cur e ly eng ag ed in t he g r oov e on
cylinder body.
● Do not reuse retaining ring.
5. Install sliding pin bolts and sliding pin boots to torque member.
6. Install torque member to axle assembly, and tighten torque
member fixing bolt to the specified torque.
CAUTION:
Before installing torque member to axle as sembly, wipe off
oil and grease on the washer seats on the axle assembly
and mounting surface of torque member.
7. Install pad retainers to torque member.
CAUTION:
When installing pad retainer, attach it firmly so that it does
not flat up higher than torque member, as shown in the figure.
8. After assembling sh ims and shim co ver to pads, asse mble it to
torque member.
9. Install cylinder body, and tighten sliding pin bolts to the specified
torque.
10. Position the metal fitt ing of brake hose by aligning with protrusions on cylinder body and tighten union bolts to specified
torque.
CAUTION:
● Assemble brake hose securely to the cylinder body.
● Do not reuse copper washer on the union bolts.
Brake Burnishing Procedu re AFS002VQ
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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 p edal /foo t ef fo rt to bri ng the vehi cle to a comple te st op f rom 50 km/h (31 MP H). Adju st
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.
Edition: 2004 September 2005 G35 Coupe
BR-33
Page 34
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030 General Specifications AFS002TU
Unit: mm (in)
Front brake Brake model CLZ31VD
Cylinder bore diameter 45.0×2 (1.772×2)
Pad
Length × width × thickness
Rotor outer diameter × thickness 320×28.0 (1 2.6 ×1.102)
Rear brake Brake model AD14VF
Cylinder bore diameter 42.86 (1.6874)
Pad
Length × width × thickness
Rotor outer diameter × thickness 308×16 (12.13× 0.63)
Master cylinder Cylinder bore diameter 25.4 (1.0)
Control valve Valve model Electric brake force distribution
Brake booster Booster model N255
Diaphragm diameter 255 (10.04)
130× 50×11.0
(5.12×1.97×0.43)
83.0 × 31.9 × 8.5
(3.27× 1.26× 0.335)
Recommended brake fluid DOT 3
Brake Pedal AFS002TV
Brake pedal free height (from dash panel top surface)
Brake pedal depressed height [under a force of 490 N (50 kg, 110 lb)
with the engine running]
Clearance between stopper rubber and the threaded end of stop lamp switch and ASCD
cancel switch
Pedal play 3 - 11 (0.12 - 0.43)
M/T model 154 - 164 (6.06 - 6.46)
A/T model 162 - 172 (6.38 - 6.77)
M/T model More than 90 (3.54)
A/T model More than 95 (3.74)
0.74 - 1.96 (0.0291 - 0.0772)
Check Valve AFS002TW
Vacuum leakage
[at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg]
Brake Booster AFS002TX
Vacuum type
Vacuum leakage
[at vacuum of – 66.7 kPa (– 500 mmHg, –19.69 inHg)]
Input rod installation standard dimension 125 (4.92)
Front Disc Brake AFS002TY
within 1.3 kpa (10 mmHg, 0.39 inHg) of vacuum for 15 sec-
onds
Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 sec-
onds
Brake model CLZ31VD
Brake pad
Disc rotor
Edition: 2004 September 2005 G35 Coupe
Standard thickness (new) 11.0 (0.433)
Repair limit thickness 2.0 (0.079)
Standard thickness (new) 28.0 (1.102)
Repair limit thickness 26.0 (1.024)
Maximum runout 0.035 (0.0014)
BR-34
Page 35
SERVICE DATA AND SPECIFICATIONS (SDS)
Rear Disc Brake AFS002TZ
Brake model AD14VF
Brake pad
Disc rotor
Standard thickness (new) 8.5 mm (0.335 in)
Repair limit thickness 2.0 mm (0.079 in)
Standard thickness (new) 16.0 mm (0.630 in)
Repair limit thickness 14.0 mm (0.551 in)
Maximum runout 0 .05 5 mm (0 .00 22 in )
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Edition: 2004 September 2005 G35 Coupe
BR-35
Page 36
SERVICE DATA AND SPECIFICATIONS (SDS)
Edition: 2004 September 2005 G35 Coupe
BR-36
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