service INFINITI FX35 2004 Service Manual

REAR DISC BRAKE
BR-29
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Revision: 2004 November 2004 FX35/FX45
5. Install sliding pin bolt and sliding pin boots to torque member.
6. Apply PBC (Poly Butyl Cuprysil) grease or silicon- based grease to the backside of pad and to both sides
of shim, and attach inner shim and shim cover to inner pad, and the outer shim and outer shim cover to
outer pad.
7. Assembling shims and shim covers to pad.
CAUTION:
When attaching pad retainer, attach it firmly so that it does
not float up higher than torque member, as shown in the fig-
ure.
8. Attach pad retainer and pad to torque member.
9. Install cylinder body. Tighten sliding pin bolts to the specified
torque.
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, fix 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 endplay is with in the specifi-
cation before measuring runout. Refer to RAX-5, "
On-Vehicle
Inspection and Service" .
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 (“MAD, DL-8700”, “AMMCO 700 and
705” or equivalent).
Thickness Inspection
Using a micrometer, check thickness of disc rotor. If thickness is out-
side the standard, 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.
PFIA0273E
Runout limit (with it
attached to the vehicle): 0.05 mm (0.0020 in)
BRA0013D
Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear
(measured at 8 positions): 0.015 mm (0.0006 in)
SBR020B

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)

BR-32
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2004 November 2004 FX35/FX45
Rear Disc BrakeAFS001NK
Brake modelAD14VE
Brake padStandard thickness (new) 8.5 mm (0.335 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotorStandard thickness (new) 16.0 mm (0.630 in)
Repair limit thickness 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions) 0.015 mm (0.0006 in)
Runout limit (with it attached to the vehicle) 0.05 mm (0.0020 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
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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

PREPARATION
BRC-5
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Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsAFS001S7
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsAFS001S8
Tool number
(Kent-Moore No.)
Tool nameDescription
ST30720000
(J 25405)
Drift
a: 77 mm (0.03 in) dia.
b: 55 mm (2.17 in) dia.
Installing rear sensor rotor ST27863000
(—)
Drift
a: 75 mm (2.95 in) dia.
b: 62 mm (2.44 in) dia.
KV40104710
(—)
Drift
a: 76 mm (2.99 in) dia.
b: 68.5 mm (2.697 in) dia.
ZZA0701D
ZZA0832D
ZZA0832D
Tool name Description
1: Flare nut crowfoot
a: 10 mm (0.39 in)
: 12 mm (0.47 in)
2: Torque wrenchRemoving and installing each brake piping
S-NT360

BRC-6
[VDC/TCS/ABS]
ON-VEHICLE SERVICE
Revision: 2004 November 2004 FX35/FX45
ON-VEHICLE SERVICEPFP:00000
Adjustment of Steering Angle Sensor Neutral PositionAFS001S9
In case of doing work that applies to the list below, make sure to adjust neutral position of steering angle sen-
sor before running vehicle.
×: Required
–: Not required
CAUTION:
To adjust neutral position of steering angle sensor, make sure to use CONSULT-II.
(Adjustment cannot be done without CONSULT-II.)
1. Stop vehicle with front wheels in straight-ahead position.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle, and turn ignition
switch ON (do not start engine).
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
3. Touch “ABS”, “WORK SUPPORT” and “ST ANGLE SENSOR ADJUSTMENT” on CONSULT-II screen in
this order. Refer to BRC-26, "
CONSULT-II BASIC OPERATION PROCEDURE" .
4. Touch “START”.
CAUTION:
Do not touch steering wheel while adjusting steering angle
sensor.
5. After approximately 10 seconds, touch “END”. (After approxi-
mately 60 seconds, it ends automatically.)
6. Turn ignition switch OFF, then turn it ON again.
CAUTION:
Be sure to carry out above operation.
7. Run vehicle with front wheels in straight-ahead position, then
stop.
8. Select “DATA MONITOR”, “SELECTION FROM MENU”, and “STR ANGLE SIG” on CONSULT-II screen.
Then make sure “STR ANGLE SIG” is within 0 ±3.5 deg. If value is more than specification, repeat steps 3
to 7.
9. Erase memory of ABS actuator and electric unit (control unit) and ECM.
10. Turn ignition switch OFF.
Calibration of Decel G-sensor (AWD Model)AFS001TQ
NOTE:
After removing/installing or replacing yaw rate/side/decel G-sensor, ABS actuator and electric unit (control
unit), suspension components, or after adjusting wheel alignment make sure to calibrate of decel G-sensor
before running vehicle.
CAUTION:
To calibrate decel G-sensor, make sure to use CONSULT-II. (Adjustment cannot be done without CON-
SULT-II.)
Situation Adjustment of Steering Angle Sensor Neutral Position
Removing/Installing ABS actuator and electric unit (control unit)−
Replacing ABS actuator and electric unit (control unit)×
Removing/Installing steering angle sensor×
Removing/Installing steering components×
Removing/Installing suspension components×
Change 4 tires to new ones –
Tire rotation–
Adjusting wheel alignment×
SFIA0371E

ON-VEHICLE SERVICE
BRC-7
[VDC/TCS/ABS]
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Revision: 2004 November 2004 FX35/FX45
1. Stop vehicle with front wheels in straight-ahead position.
CAUTION:

The work should be done at a horizontal place when vehicle is in the unloaded vehicle condi-
tion.

Keep all tires inflated to correct pressures. Adjust the tire pressure to the specified pressure
value.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle, and turn ignition
switch ON (do not start engine).
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
3. Touch “ABS”, “WORK SUPPORT” and “DECEL G-SEN CALIBRATION” on CONSULT-II screen in this
order. Refer to BRC-26, "
CONSULT-II BASIC OPERATION PROCEDURE" .
4. Touch “START”.
CAUTION:
Set vehicle as shown in the display.
5. After approximately 10 seconds, touch “END”. (After approxi-
mately 60 seconds, it ends automatically.)
6. Turn ignition switch OFF, then turn it ON again.
CAUTION:
Be sure to carry out above operation.
7. Run vehicle with front wheels in straight-ahead position, then
stop.
8. Select “DATA MONITOR”, “SELECTION FROM MENU”, and
“DECEL G-SEN” on CONSULT-II screen. Then make sure “DECEL G-SEN” is within 0 ±0.08 G. If value is
more than specification, repeat steps 3 to 7.
9. Erase memory of ABS actuator and electric unit (control unit) and ECM.
10. Turn ignition switch OFF.
SFIA1162E

SENSOR ROTOR
BRC-59
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Revision: 2004 November 2004 FX35/FX45
SENSOR ROTORPFP:47970
Removal and InstallationAFS001Z4
REMOVAL
Front
Sensor rotor cannot be disassembled. To replace sensor rotor, replace wheel hub and bearing assembly.
Refer to FA X - 4 , "
Removal and Installation" (2WD model), FA X - 1 0 , "Removal and Installation" (AWD model).
Rear

Follow procedure below to remove rear sensor rotor.
–Remove side flange. Refer to RFD-9, "SIDE OIL SEAL" .
–Using a bearing replacer and puller, remove sensor rotor from side flange.
INSTALLATION
Front
Sensor rotor cannot be disassembled. To replace sensor rotor, replace wheel hub and bearing assembly.
Refer to FA X - 4 , "
Removal and Installation" (2WD model), FA X - 1 0 , "Removal and Installation" (AWD model).
Rear

Follow procedure below to install rear sensor rotor.
–Using a drift (special service tool), press rear sensor rotor onto
side flange.
–Install side flange. Refer to RFD-9, "SIDE OIL SEAL" .
BRG1210D

BRC-60
[VDC/TCS/ABS]
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)
Revision: 2004 November 2004 FX35/FX45
ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)PFP:47660
Removal and InstallationAFS001Z5
REMOVAL
1. Disconnect ABS actuator and electric unit (control unit) connector.
2. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit).
3. Remove LH side fender protector. Refer to EI-25, "
FENDER PROTECTOR" .
4. Remove ABS actuator and electric unit (control unit) mounting nuts.
5. Remove ABS actuator and electric unit (control unit) from vehicle.
CAUTION:
Be careful of the following when removing ABS actuator and electric unit (control unit).

If the part number on the part number label (pasted on actuator upper surface) is the same, ABS
actuator and electric unit (control unit) cannot be used on another vehicle.
If it is used on another vehicle, ABS warning lamp, SLIP indicator lamp and VDC OFF indicator
lamp may turn ON or VDC/TCS/ABS may not operate normally.
When replacing ABS actuator and electric unit (control unit), must use new service parts.

Before servicing, disconnect battery cables.

To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being dam-
aged. To install, use a flare nut torque wrench (commercial service tool) and tighten to the speci-
fied torque.

Do not apply excessive impact to actuator, such as dropping it.

Do not remove and install ABS actuator and electric unit (control unit) by holding harness.
INSTALLATION
To install, follow procedure for removal in reverse order.
CAUTION:
Be careful of the following when installing ABS actuator and electric unit (control unit).

Tighten the mounting bolts and nuts to the specified torque.

After the work, bleed air from brake piping. Refer to BR-10, "Bleeding Brake System" .
PFIA0601E