Engine INFINITI FX35 2004 Service Manual

BODY REPAIR
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Revision: 2004 November2004 FX35/FX45
ENGINE COMPARTMENT
Measurement
SIIA2260E

BR-6
BRAKE PEDAL
Revision: 2004 November 2004 FX35/FX45
BRAKE PEDALPFP:46501
Inspection and AdjustmentAFS001MT
PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL
DEPRESSED
1. Check brake pedal height from dash lower panel.
2. Adjust height referring to the following specifications.
SFIA1450E
HBrake pedal free height (from dash lower panel
top surface)161.5 − 171.5 mm (6.36 − 6.75 in)
DBrake pedal depressed height [under a force of
490 N (50 kg, 110 lb) with engine running]More than 80 mm (3.15 in)
CClearance between bracket and the threaded end
of stop lamp switch or ASCD cancel switch (or
brake switch)0.74 − 1.96 mm (0.0291−0.0772 in)
A Pedal play 3 − 11 mm (0.12 − 0.43 in)

BRAKE PEDAL
BR-7
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Revision: 2004 November 2004 FX35/FX45
ADJUSTMENT
1. Loosen stop lamp switch and ASCD cancel switch (or brake
switch) by turning it counterclockwise by 45°.
2. Loosen lock nut (A) on input rod, then rotate input rod to set
pedal to the specified height, and tighten lock nut (A).
CAUTION:
Make sure the threaded end of input rod stays inside clevis.
3. With pedal pulled and held by hand, press stop lamp switch and
ASCD cancel switch (or brake switch) until its threaded end con-
tacts stopper rubber.
4. With the threaded end of stop lamp switch and ASCD cancel
switch (or brake switch) contacting stopper rubber, rotate 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 (or brake switch) is within the standard.
5. Check pedal play.
CAUTION:
Make sure that stop lamps go off when pedal is released.
6. Start engine to check brake pedal depressed height.
Removal and InstallationAFS001MU
COMPONENT PARTS LOCATION
Lock nut (A) :
Refer to BR-16, "
Removal and Installation"
SFIA0160E
SFIA1940E

BR-12
BRAKE PIPING AND HOSE
Revision: 2004 November 2004 FX35/FX45
Removal and Installation of Rear Brake Piping and Brake Hose AFS001N0
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 bolt.
4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION
1. Install brake hose to caliper assembly positioning hole and
tighten union bolt to the specified torque.
NOTE:
Do not reuse copper washer.
2. Install brake hose to brake tube, partially tighten flare nut as far
as possible by hand, then tighten bolt to the specified torque.
3. Using a flare nut wrench, tighten flare nut to the specified
torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
Inspection After InstallationAFS001N1
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact
with other parts, and loose connections. Replace any 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.: 23.5 N·m (2.4 kg-m, 17 ft-lb)
SFIA1942E

BRAKE BOOSTER
BR-15
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Revision: 2004 November 2004 FX35/FX45
BRAKE BOOSTERPFP:47200
On-Vehicle ServiceAFS001N6
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

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.

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

VACUUM LINES
BR-19
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Revision: 2004 November 2004 FX35/FX45
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
SFIA0210E

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-31
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Revision: 2004 November 2004 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsAFS001NF
Unit: mm (in)
Brake PedalAFS001NG
Brake BoosterAFS001NH
Va c u u m t y p e
Check ValveAFS001NI
Front Disc BrakeAFS001NJ
Front brake Brake model CLZ31VC
Rotor outer diameter × thickness 320 × 28 (12.60 × 1.10)
Pad Length × width × thickness 111.0 × 73.5 × 9.5 (4.73 × 2.894 × 0.374)
Cylinder bore diameter 63.6 (2.504)
Rear brake Brake model AD14VE
Rotor outer diameter × thickness 308 × 16 (12.13 × 0.63)
Pad Length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Cylinder bore diameter 42.86 (1.6874)
Master cylinder Cylinder bore diameter 25.4 (1.00)
Control valve Valve model Electric brake force distribution
Brake booster Booster model C215T
Diaphragm diameterPrimary 228.5 (9.0)
Secondary 203.0 (8.0)
Recommended brake fluidDOT 3
Brake pedal height (from dash panel top surface) 161.5 − 171.5 mm (6.36 − 6.75 in)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb)
with engine running]More than 80 mm (3.15 in)
Clearance between stopper rubber and the threaded end of
stop lamp switch 0.74 − 1.96 mm (0.0291 − 0.0772 in)
Pedal play 3 − 11 mm (0.12 − 0.43 in)
Input rod installation standard dimension 15.6 − 15.9 mm (0.614 − 0.626 in)
Vacuum leakage
[at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg)]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Brake modelCLZ31VC
Brake padStandard thickness (new) 9.5 mm (0.374 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotorStandard thickness (new) 28.0 mm (1.102 in)
Repair limit thickness 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions) 0.015mm (0.0006 in)
Runout limit (with it attached to the vehicle) 0.04 mm (0.0016 in)

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION BRC
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BRC
Revision: 2004 November 2004 FX35/FX45
BRAKE CONTROL SYSTEM
VDC/TCS/ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 3
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 5
ON-VEHICLE SERVICE ............................................. 6
Adjustment of Steering Angle Sensor Neutral Posi-
tion ........................................................................... 6
Calibration of Decel G-sensor (AWD Model) ............ 6
SYSTEM DESCRIPTION ............................................ 8
System Diagram ....................................................... 8
VDC Function ........................................................... 8
TCS Function ........................................................... 8
ABS Function ........................................................... 8
EBD Function ........................................................... 9
Fail-Safe Function .................................................... 9
VDC / TCS SYSTEM ............................................. 9
ABS, EBD SYSTEM .............................................. 9
Hydraulic Circuit Diagram ...................................... 10
CAN COMMUNICATION ...........................................11
System Description ................................................. 11
TROUBLE DIAGNOSIS ............................................ 12
How to Proceed With Diagnosis ............................. 12
BASIC CONCEPT ............................................... 12
DIAGNOSIS FLOWCHART ................................ 13
ASKING COMPLAINTS ...................................... 14
EXAMPLE OF DIAGNOSIS SHEET ................... 14
Component Installation Location ............................ 15
Schematic .............................................................. 16
Wiring Diagram — VDC — ..................................... 17
Control Unit Input/Output Signal Standard ............. 23
REFERENCE VALUE FROM CONSULT-II ......... 23
CONSULT-II Functions ........................................... 25
CONSULT-II MAIN FUNCTION ........................... 25
CONSULT-II BASIC OPERATION PROCEDURE ... 26
SELF-DIAGNOSIS .............................................. 27
DATA MONITOR ................................................. 30
ACTIVE TEST ..................................................... 33
For Fast and Accurate Diagnosis ........................... 35
PRECAUTIONS FOR DIAGNOSIS ..................... 35
Basic Inspection ..................................................... 36
BASIC INSPECTION 1: BRAKE FLUID
AMOUNT, LEAKS, AND BRAKE PADS INSPEC-
TION .................................................................... 36
BASIC INSPECTION 2: POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 36
BASIC INSPECTION 3: ABS WARNING LAMP,
VDC OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAKE WARNING LAMP INSPEC-
TION .................................................................... 37
Inspection 1: Wheel Sensor System ....................... 37
Inspection 2: Engine System .................................. 39
Inspection 3: VDC/TCS/ABS Control Unit System ... 40
Inspection 4: Pressure Sensor System .................. 40
Inspection 5: Steering Angle Sensor System ......... 42
Inspection 6: Yaw Rate/Side G-Sensor (2WD
model), Yaw Rate/Side/Decel G-sensor (AWD mod-
els) System ............................................................. 44
Inspection 7: Solenoid and VDC Change-Over
Valve System .......................................................... 46
Inspection 8: Actuator Motor System ...................... 47
Inspection 9: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground System .......... 48
Inspection 10: Stop Lamp Switch System .............. 50
Inspection 11: Brake Fluid Level Switch System .... 51
Inspection 12: When “ST ANG SEN SIGNAL”
Appears on Self-Diagnosis Results Display ........... 52
Inspection 13: When “DECEL G SEN SET” Appears
on Self-Diagnosis Results Display (AWD Model) ... 52
Inspection 14: CAN Communication System .......... 53
Component Inspection ............................................ 53
VDC OFF SWITCH ............................................. 53
Symptom 1: Excessive ABS Function Operation

PRECAUTIONS
BRC-3
[VDC/TCS/ABS]
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Revision: 2004 November 2004 FX35/FX45
[VDC/TCS/ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AFS00289
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:

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.

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.

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 SystemAFS001S3

Recommended fluid is brake fluid “DOT 3”.

Do not reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off
and flush area with water immediately.

Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause
improper operation.

Using a flare nut crowfoot and torque wrench, securely tighten
brake tube flare nuts.

Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction
is detected, replace part with a new one.

Before working, turn ignition switch OFF and disconnect electri-
cal connectors of ABS actuator and electric unit (control unit) or
battery negative terminal.

When installing brake piping, be sure to check torque.
Precautions for Brake ControlAFS001S4

During VDC/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This
is normal.

Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may
be heard from engine room. This is a normal status of operation check.

Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.

When an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnostic servicing. Besides electrical system inspection, check booster operation, brake fluid level, and
fluid leaks.

If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.

If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, VDC/TCS/ABS
function may have a malfunction or error.
SBR686C

BRC-4
[VDC/TCS/ABS]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45

If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.

If the following components are replaced with non-genuine components or converted, VDC OFF indicator
lamp and SLIP indicator lamp may turn on or the VDC system may not operate properly. Components
related to suspension (Shock Absorber, Strut, Spring, Bush, etc.), Tires, wheels (exclude specified size),
components related to brake (Pad, Rotor, Caliper, etc.), components related to engine (Muffler, ECM,
etc.), components related to body reinforcement (Roll bar, Tower bar, etc.).

Driving in the condition of breakage or excessive wear of suspension, tires or components related to the
brakes may cause VDC OFF indicator lamp and SLIP indicator lamp turn on, and the VDC system may
not operate properly.

When the TCS or VDC is activated by sudden acceleration or sudden turn, some noise may occur. The
noise is a result of the normal operation of the TCS and VDC.

When driving on roads which have extreme slopes (such as mountainous roads) or high banks (such as
sharp carves on a freeway), the VDC may not operate normally, or VDC OFF indicator lamp and SLIP
indicator lamp may turn on. However, this is not a malfunction, if normal operation can be resumed after
restarting engine.

Sudden turns (such as spin turns, acceleration turns), drifting, etc. When VDC function is OFF (VDC SW
ON) may cause the G -sensor system indicate a malfunction. However, this is not a malfunction, if normal
operation can be resumed after restarting engine.