engine INFINITI M35 2007 Factory Service Manual

BR-6
BRAKE PEDAL
Revision: 2007 April2007 M35/M45
BRAKE PEDALPFP:46501
Inspection and AdjustmentNFS000RT
Play and clearance inspection between brake pedal and floor panel with pedal depressed.

Check brake pedal play.

Check brake pedal height from dash lower panel (1).

Adjust height referring to the following specifications.
ADJUSTMENT
1. Loosen stop lamp switch and brake switch by turning it counter-
clockwise by 45°.
2. Loosen lock nut (A) on the input rod to rotate input rod for adjust-
ing brake pedal height to the specified one, and tighten lock nut
(A). Refer to BR-18, "
COMPONENTS" .
CAUTION:
Make sure the threaded end of input rod stays inside clevis.
3. With the pedal pulled and held by hand, press stop lamp switch
and brake switch until its threaded end contacts stopper.
4. With the threaded end of the stop lamp switch and brake switch
contacting the bracket, rotate the switch clockwise by 45° to
secure.
CAUTION:
Make sure that the clearance “C” between bracket and end
of stop lamp switch and brake switch is within the standard.
5. Check pedal play.
CAUTION:
Make sure that stop lamps goes off when pedal is released.
6. Start engine to check brake pedal depression height when
depressed. Refer to BR-6, "
Inspection and Adjustment" .
H1Brake pedal height
[from dash lower panel (1) top surface]157 − 167 mm (6.18 −
6.57 in)
H
2
Depressed brake pedal height
[under a force of 490 N (50 kg, 110 lb) with
engine running]90 mm (3.54 in) or more
CClearance between threaded end of the stop
lamp switch/brake switch (2) and bracket (3)0.74 − 1.96 mm (0.0291 −
0.0772 in)
A Pedal play3 − 11 mm (0.12 − 0.43
in)
SFIA2743J
PFIA0824E

BR-8
BRAKE PEDAL
Revision: 2007 April2007 M35/M45
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
2. Remove steering column assembly. Refer to PS-13, "
STEERING COLUMN" .
3. Disconnect stop lamp switch and brake switch connector.
4. Remove stop lamp switch and brake switch from brake pedal assembly.
5. Disconnect brake pedal stroke sensor connector.(With pre-crash seat belt)
CAUTION:
Brake pedal stroke sensor is not detachable. Do not detach it.
6. Remove snap pin and clevis pin from clevis of brake booster.
7. Remove brake pedal assembly mounting nuts. Pull brake booster toward engine room to the extent that
does not deform brake tube.
8. Remove brake booster clevis from input rod.
9. Remove mounting bolt and then remove brake pedal assembly from vehicle.
INSPECTION AFTER REMOVAL

Check the items below. If any is found, replace brake pedal
assembly.
–Check brake pedal upper rivet for deformation.
–Make sure that joint length “L” of sub-bracket and sliding plate is
4 mm (0.16 in) or more.
–Check brake pedal for bend, damage, and cracks on the welded
parts.

Check clevis pin and plastic stopper for damage and deforma-
tion. If any is found, replace clevis pin.
INSTALLATION
Installation is the reverse order of removal. Tightening torques for brake pedal assembly mounting nuts and
bolt are referred to BR-7, "
COMPONENTS" . Tightening torque for lock nut is referred to BR-18, "COMPO-
NENTS" .

Adjust brake pedal height after installing brake pedal assembly to vehicle. Refer to BR-6, "Inspection and
Adjustment" .
SFIA2487E
SBR997

BRAKE FLUID
BR-9
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
BRAKE FLUIDPFP:KN100
On-Board Inspection NFS000RV
CHECKING BRAKE FLUID LEVEL

Make sure that a brake fluid level in reservoir tank is within the
standard (between MAX and MIN lines).

Visually check around reservoir tank for fluid leakage.

If the level is excessively low, check brake system for leakage.

Release parking brake pedal and see if brake warning lamp
goes off. If not, check brake system for fluid leakage.
Checking Brake LineNFS000RW
CAUTION:
If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged
parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Drain and RefillNFS000RX
CAUTION:

Refill with new brake fluid “DOT 3”.

Never reuse drained brake fluid.

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.

Before working, disconnect connectors of ABS actuator and electric unit (control unit) or battery
cable from the negative terminal.
1. Connect a vinyl tube to bleed valve.
2. Depress brake pedal, loosen bleed valve, and gradually remove
brake fluid.
SFIA2484E
SBR389C
BRA0007D

BRAKE TUBE AND HOSE
BR-13
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
2. Disconnect brake hose from brake tube, using a flare nut wrench.
3. Remove union bolts, and then remove brake hose from brake
caliper assembly.
4. Remove lock plate and then remove brake hose from vehicle.
INSTALLATION
1. Assemble the union bolt and copper washer to the brake hose.
CAUTION:
Do not reuse copper washer.
2. Attach L-shape metal fitting of the brake hose to brake caliper assembly positioning hole, and then tighten
union bolt to the specified torque. Refer to BR-11, "
Hydraulic Circuit" .
3. Connect brake hose to brake tube, partially tighten flare nut by hand as much as possible, then secure it
to the bracket with lock plate.
4. Using a flare nut torque wrench, tighten flare nut to the specified torque. Refer to BR-11, "
Hydraulic Cir-
cuit" .
5. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
Inspection after InstallationNFS000S2
CAUTION:
Brake tubes and hoses are important safety parts. Always disassemble the parts and retighten their fit-
tings, if a brake fluid leak is detected. Replace applicable part with a new one, if damaged part is
detected.
1. Check brake lines (tubes and hoses) and connections for fluid leakage, damage, twists, deformation, con-
tacts 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, then check each part for fluid leakage.
SFIA2049E

BRAKE BOOSTER
BR-17
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
BRAKE BOOSTERPFP:47200
On-Board Inspection and ServiceNFS000S7
OPERATION CHECK
With engine stopped, change vacuum to atmospheric pressure by
depressing brake pedal several times. Then with brake pedal fully
depressed, start engine and when vacuum pressure reaches the
standard, make sure that clearance between brake pedal and floor
panel decreases.
AIR TIGHT CHECK

Run engine at idle for approximately 1 minute, and stop it after
applying vacuum to booster. Depress brake pedal normally to
change vacuum to atmospheric pressure. Make sure that dis-
tance at intervals of 5 seconds 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.
BRA0037D
SBR365AA

BR-18
BRAKE BOOSTER
Revision: 2007 April2007 M35/M45
Removal and InstallationNFS000S8
COMPONENTS
CAUTION:

Be careful not to deform or bend brake tube while removing and installing brake booster.

Replace clevis pin if it is damaged.

Be careful not to damage brake booster stud bolt threads. If brake booster is tilted during installa-
tion, the dash panel may damage the threads.
REMOVAL
1. Remove cowl top. Refer to EI-18, "Removal and Installation" .
2. Remove brake master cylinder. Refer to BR-14, "
Removal and
Installation" .
3. Disconnect front left brake tube from ABS actuator and electric
unit (control unit). Refer to BR-11, "
Hydraulic Circuit" .
4. Remove vacuum hose from brake booster. Refer to BR-20,
"Components" .
5. Remove snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster from dash panel in engine room side.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle. At this time, make sure that a gasket
between booster assembly and dash panel is installed.
CAUTION:
Always install gasket between brake booster and dash
panel.
3. Connect brake pedal with clevis of input rod.
1. Master cylinder assembly 2. Brake booster 3. Lock nut
4. Brake pedal 5. Gasket
Refer to GI-11, "
Components" , for the symbols in the figure.
SFIA2956E
SFIA2044E
Length “B” : 125 mm (4.92 in)
SGIA0060E

BR-20
VACUUM LINES
Revision: 2007 April2007 M35/M45
VACUUM LINESPFP:41920
ComponentsNFS000S9
VK45DE ENGINE MODELS
VQ35DE ENGINE MODELS
SFIA2957E
1. Clamp 2. Vacuum hose 3. Engine direction indicator stamp
(Built in check valve)
4. Clip 5. Vacuum piping 6. Grommet (Vacuum hose side)
7. Grommet (Cowl top assy side) 8. For intake manifold 9. For brake booster
SFIA2958E
1. Clamp 2. Vacuum hose 3. Engine direction indicator stamp
(Built in check valve)
4. Clip 5. Vacuum piping 6. Grommet (Vacuum hose side)
7. Grommet (Cowl top assy side) 8. For intake manifold 9. For brake booster

VACUUM LINES
BR-21
C
D
E
G
H
I
J
K
L
MA
B
BR
Revision: 2007 April2007 M35/M45
Removal and InstallationNFS000SA
CAUTION:

Because vacuum hose contains a check valve, it must be
installed in the correct position. Refer to the stamp to con-
firm correct installation. Brake booster will not operate nor-
mally if the hose is installed in the wrong direction.

Insert vacuum hose at least 24 mm (0.94 in).

Do not use lubricating oil during assembly.
InspectionNFS000SB
VISUAL INSPECTION
Check for correct assembly, damage and deterioration.
CHECK VALVE INSPECTION
Airtightness Inspection
Use a handy vacuum pump to check.

Replace vacuum hose assembly if vacuum hose and check
valve are malfunctioning.
SBR225B
When connected to the booster side (1):
Vacuum should decrease 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 the engine side (2):
Vacuum should not exist.
SFIA0210E

BR-34
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2007 April2007 M35/M45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsNFS000SM
Unit: mm (in)
Brake PedalNFS000SN
Unit: mm (in)
Brake BoosterNFS000SO
Vacuum type
Unit: mm (in)
Check ValveNFS000SP
Front Disc BrakeNFS000SQ
Unit: mm (in)
Rear Disc BrakeNFS000SR
Unit: mm (in) Front brakeCylinder bore diameter 45.0 (1.772) × 2
Pad length × width × thickness 132.0 × 50.0 × 11.0 (5.20 × 1.969 × 0.433)
Rotor outer diameter × thickness 320 × 28 (12.60 × 1.10)
Rear brake Cylinder bore diameter 42.86 (1.687)
Pad length × width × thickness 83.0 × 31.9 × 8.5 (3.268 × 1.256 × 0.335)
Rotor outer diameter × thickness 308 × 16 (12.13 × 0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electric brake force distribution
Brake booster Diaphragm diameter 255 (10)
Recommended brake fluid DOT 3
Brake pedal height (from dash lower panel top surface) 157 − 167 (6.18 − 6.57)
Depressed pedal height
[under a force of 490 N (50 kg, 110 lb) with engine running]90 (3.54) or more
Clearance between threaded end of the stop lamp switch/brake
switch and bracket 0.74 − 1.96 (0.0291 −0.0772)
Pedal play3 − 11 (0.12 − 0.43)
Input rod installation standard dimension 125 (4.92)
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 padStandard thickness 11.0 (0.433)
Repair limit thickness 2.0 (0.079)
Disc rotorStandard thickness 28.0 (1.102)
Wear limit 26.0 (1.024)
Thickness variation (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.035 (0.0014)
Brake padStandard thickness 8.5 (0.335)
Repair limit thickness 2.0 (0.079)
Disc rotorStandard thickness 16.0 (0.631)
Wear limit 14.0 (0.551)
Thickness variation (measured at 8 positions) 0.015 (0.0006)
Runout limit (with it attached to the vehicle) 0.055 (0.0022)

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BRC
A
B
BRC
Revision: 2007 April2007 M35/M45
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 Procedures without Cowl Top Cover ..... 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 5
ON-VEHICLE SERVICE ............................................. 6
Adjustment of Steering Angle Sensor Neutral Posi-
tion ........................................................................... 6
SYSTEM DESCRIPTION ............................................ 7
System Diagram ....................................................... 7
Functions .................................................................. 7
ABS ....................................................................... 7
EBD ....................................................................... 7
TCS ....................................................................... 8
VDC ....................................................................... 8
ECD ....................................................................... 8
Operation That Is Not "System Error" ...................... 8
ABS ....................................................................... 8
TCS ....................................................................... 8
VDC ....................................................................... 8
Hydraulic Circuit Diagram ........................................ 9
CAN Communication ................................................ 9
SYSTEM DESCRIPTION ...................................... 9
TROUBLE DIAGNOSIS ............................................ 10
Fail-Safe Function .................................................. 10
ABS, EBD SYSTEM ............................................ 10
VDC/TCS ............................................................ 10
How to Perform Trouble Diagnoses ....................... 10
BASIC CONCEPT ............................................... 10
DIAGNOSIS FLOW CHART ................................ 11
ASKING COMPLAINTS ...................................... 12
EXAMPLE OF DIAGNOSIS WORKSHEET ........ 12
Component Parts Location ..................................... 13
Schematic .............................................................. 14Wiring Diagram — VDC — ..................................... 15
Control Unit Input/Output Signal Standard ............. 21
REFERENCE VALUE FROM CONSULT-II ......... 21
CONSULT-II Functions (ABS) ................................ 23
CONSULT-II MAIN FUNCTION ........................... 23
CONSULT-II SETTING PROCEDURE ................ 23
Self-Diagnosis ........................................................ 24
OPERATION PROCEDURE ................................ 24
ERASE MEMORY ............................................... 24
DISPLAY ITEM LIST ........................................... 25
Data Monitor ........................................................... 28
OPERATION PROCEDURE ................................ 28
DISPLAY ITEM LIST ........................................... 28
Active Test .............................................................. 30
OPERATION PROCEDURE ................................ 30
TEST ITEMS ....................................................... 31
For Fast and Accurate Diagnosis ........................... 32
PRECAUTIONS FOR DIAGNOSIS ..................... 32
Basic Inspection ..................................................... 33
BASIC INSPECTION 1: BRAKE FLUID LEVEL,
LEAK INSPECTION AND BRAKE PAD .............. 33
BASIC INSPECTION 2: LOOSENESS OF
POWER SYSTEM TERMINALS AND BATTERY ... 33
BASIC INSPECTION 3: ABS WARNING LAMP,
BRAKE WARNING LAMP, VDC OFF INDICATOR
LAMP AND SLIP INDICATOR LAMP .................. 33
TROUBLE DIAGNOSIS FOR SYSTEM .................... 34
Wheel Sensor Circuit .............................................. 34
INSPECTION PROCEDURE .............................. 34
Engine System ....................................................... 36
INSPECTION PROCEDURE .............................. 36
ABS Actuator and Electric Unit (Control Unit) ........ 36
INSPECTION PROCEDURE .............................. 36
ABS Actuator and Electric Unit (Control Unit) Power
Supply and Ground Circuit ..................................... 37
INSPECTION PROCEDURE .............................. 37
ABS Motor and Motor Relay Circuit ........................ 38
INSPECTION PROCEDURE .............................. 38
Solenoid, VDC Change-Over Valve and Actuator
Relay Circuit ........................................................... 39