air INFINITI FX35 2004 Service Manual

BR-26
REAR DISC BRAKE
Revision: 2004 November 2004 FX35/FX45
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:

While removing cylinder body, never depress brake pedal because piston will pop out.

It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.

Do not damage piston boot.

If any shim is subject to serious corrosion, replace it with a new one.

Always replace shims and shim covers as a set when replacing brake pads.

Burnish brake contact surface after refinishing or replacing rotors, after replacing pads, or it a soft
pedal occurs at very low mileage. Refer to BR-29, "
BRAKE BURNISHING PROCEDURE"
Removal and Installation of Brake PadAFS001NC
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove sliding pin bolt (one on top).
3. Suspend cylinder body with a wire, and remove pads, pad retainers, shim from torque member.
INSTALLATION
1. 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 attach the outer shim and outer shim
cover to outer pad.
2. Install pad retainer and mount pad to torque member.
3. Push piston in so that pad is firmly attached and mount cylinder body to torque member.
NOTE:
Using a disc brake piston tool (commercial service tool), etc., makes it easier to push in piston.
CAUTION:
By pushing in piston, brake fluid returns to master cylinder reservoir tank. Watch the level of the
surface of reservoir tank.
4. Install sliding pin bolt (one on top) and tighten to the specified torque.
5. Check brake for drag.
6. Install tires to the vehicle.
Removal and Installation of Brake Caliper AssemblyAFS001ND
REMOVAL
1. Remove tires from vehicle with power tool.
2. Drain brake fluid. Refer to BR-9, "
Drain and Refill" .
3. Remove union bolt and torque member bolts, and remove brake
caliper assembly from the vehicle.
4. Remove disc rotor.
INSTALLATION
CAUTION:

Refill with new brake fluid “DOT 3”.

Do not reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly to the vehicle, and tighten bolts to the specified torque.
PFIA0413E

REAR DISC BRAKE
BR-27
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Revision: 2004 November 2004 FX35/FX45
CAUTION:
Before installing caliper assembly to the vehicle, wipe off oil and grease on washer seats on axle
assembly and mounting surface of caliper assembly.
3. Install brake hose to caliper assembly and tighten union bolt to the specified torque.
CAUTION:

Do not reuse copper washer for union bolt.

Securely attach brake hose to protrusion on caliper assembly.
4. Refill new brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake System" .
5. Install tires to the vehicle.
Disassembly and Assembly of Brake Caliper AssemblyAFS001NE
DISASSEMBLY
1. Remove sliding pin bolt, and then remove pad, shim, shim cover, and pad retainer from torque member
and cylinder.
2. Remove sliding pin boot from torque member.
3. As shown in the figure, using a flat-bladed screwdriver, remove
retaining ring from cylinder body.
4. Place a wooden block as shown in the figure, and blow air from
union bolt mounting hole to remove pistons and piston boots.
CAUTION:
Do not get your fingers caught in piston.
5. Using a flat-bladed screwdriver, remove piston seals from cylin-
der body.
CAUTION:
Be careful not to damage cylinder inner wall.
CALIPER INSPECTION
Cylinder Body
CAUTION:

Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene.

Check inside surface of cylinder for score, rust wear, damage or foreign materials. If any of the
above conditions are observed, replace cylinder body.
SBR028A
BRD0041D
PFIA0269E

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
[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-12
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2004 November 2004 FX35/FX45
TROUBLE DIAGNOSISPFP:00004
How to Proceed With DiagnosisAFS001SL
BASIC CONCEPT

Most important point to perform diagnosis is to understand systems (control and mechanism) in vehicle
thoroughly.

It is also important to clarify customer complaints before inspec-
tion.
First of all, reproduce symptom, and understand it fully.
Ask customer about his/her complaints carefully. In some cases,
it will be necessary to check symptom by driving vehicle with
customer.
NOTE:
Customers are not professionals. Do not assume “maybe cus-
tomer means...” or “maybe customer mentioned this symptom”.

It is essential to check symptoms right from beginning in order to
repair a malfunction completely.
For an intermittent malfunction, it is important to reproduce
symptom based on interview with customer and past examples.
Do not perform inspection on ad hoc basis. Most intermittent
malfunctions are caused by poor contacts. In this case, it will be
effective to shake suspected harness or connector by hand.
When repairs are performed without any symptom check, no
one can judge if malfunction has actually been eliminated.

After diagnosis, make sure to carry out “erase memory”. Refer to
BRC-27, "
SELF-DIAGNOSIS" .

For an intermittent malfunction, move harness or harness con-
nector by hand to check poor contact or false open circuit.

Always read “GI General Information” to confirm general precautions. Refer to GI-4, "General Precau-
tions" .
SEF234G
SEF233G

TROUBLE DIAGNOSIS
BRC-27
[VDC/TCS/ABS]
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Revision: 2004 November 2004 FX35/FX45
6. Select the required diagnostic location from the “SELECT DIAG
MODE” screen.
For further information, see CONSULT-II Operation Manual.
SELF-DIAGNOSIS
Description

If an error is detected in the system, ABS warning lamp, VDC OFF indicator lamp and SLIP indicator lamp
on the combination meter turn on. In this case, perform self-diagnosis as follows:

While CONSULT-II is used, ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp may be
turned on in a case of no malfunctioning.
Operation Procedure
1. Turn ignition switch OFF.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector.
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. Turn ignition switch ON.
4. Start engine and drive at approximately 30 km/h (19 MPH) or more for approximately 1 minute.
5. After stopping vehicle, with the engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-
DIAG RESULTS” in order on the CONSULT-II screen.
CAUTION:
If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on the
ignition switch, “ABS” might not be displayed in the System Selection screen. In this case, repeat
the operation from step 1. If it cannot be shown after several attempts, ABS actuator and electric
unit (control unit) may have malfunctioned.
6. The self-diagnostic results are displayed. (If necessary, the self-diagnostic results can be printed out by
touching “PRINT”.)

When “NO FAILURE” is displayed, check ABS warning lamp, VDC OFF indicator lamp and SLIP indica-
tor lamp.
7. Perform the appropriate inspection from the display item list, and repair or replace the malfunctioning
component.
8. Drive the vehicle at approximately 30 km/h (19 MPH) or more for approximately 1 minute.
CAUTION:

In a case that a wheel sensor is malfunctioning, ABS warning lamp, VDC OFF indicator lamp,
SLIP indicator lamp will turn on. If vehicle is not driven at approximately 30 km/h (19 MPH) or
more for at least approximately 1 minute after repair of the wheel sensor system, ABS warning
lamp, VDC OFF indicator lamp and SLIP indicator lamp may not turn off even if everything is
normal. Check again to make sure that there is no malfunction on other parts.
9. Turn ignition switch OFF to prepare for erasing the memory.
10. Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE
MEMORY” in order on the CONSULT-II screen to erase the error memory.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
CAUTION:
If the error memory is not erased, re-perform the operation from step 5.
11. For the final inspection, drive at approximately 30 km/h (19 MPH) or more for approximately 1 minute and
confirm that ABS warning lamp, VDC OFF indicator lamp and SLIP indicator lamp are OFF.
SFIA2436E

BRC-30
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2004 November 2004 FX35/FX45
Note 1: After completing repairs of shorted sensor circuit, when turn ignition switch ON, ABS warning lamp
turned on. Check that ABS warning lamp turned off while driving vehicle at approximately 30 km/h (19 MPH)
or more for approximately 1 minute according to self-diagnosis procedure. In addition, if wheel sensor 2 is dis-
played for wheels, check wheel sensor circuit and also check ABS actuator and electric unit (control unit)
power voltage.
Note 2: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for
CAN communication line first.
Note 3: “ACTUATOR RLY” on the CONSULT-II self-diagnostic results indicates the malfunction of actuator
relay or circuit. Actuator relay is imbedded in ABS actuator and electric unit (control unit).
DATA MONITOR
Operation Procedure
1. After turning OFF ignition switch, connect CONSULT-II and CONVERTER to data link connector.
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.
2. Turn ignition switch ON.
3. Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on the CONSULT-II screen.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
CAN COMM CIRCUIT
[U1000]

CAN communication line is open or shorted.

ABS actuator and electric unit (control unit) internal malfunc-
tion

Battery voltage for EMC is suddenly interrupted for approxi-
mately 0.5 seconds or more.BRC-53, "
Inspection 14:
CAN Communication
System" (Note 2)
BR FLUID LEVEL LOW
[C1155]Brake fluid level drops or circuit between ABS actuator and elec-
tric unit (control unit) and brake fluid level switch is open or
shorted.BRC-51, "
Inspection 11:
Brake Fluid Level Switch
System"
VARIANT CODING
[C1170]V coding is not functioning.ABS actuator and elec-
tric unit (control unit) and
circuit
G - SENSOR (AWD model)
[C1113]Decel G sensor is malfunctioning, or signal line of Decel G sen-
sor is open or shorted.BRC-44, "
Inspection 6:
Yaw Rate/Side G-Sensor
(2WD model), Yaw Rate/
Side/Decel G-sensor
(AWD models) System"
ENGINE SIGNAL 1
[C1130]Based on the signal from ECM, ABS actuator and electric unit
(control unit) judges that engine fuel cut system is malfunction-
ing.–
ENGINE SIGNAL 2
[C1131]Based on the signal from ECM, ABS actuator and electric unit
(control unit) judges that engine ETC system is malfunctioning.–
ENGINE SIGNAL 3
[C1132]Based on the signal from ECM, ABS actuator and electric unit
(control unit) judges that engine CAN system is malfunctioning.–
ENGINE SIGNAL 4
[C1133]Based on the signal from ECM, ABS actuator and electric unit
(control unit) judges that engine torque down system is malfunc-
tioning.–
ENGINE SIGNAL 6
[C1136]Based on the signal from ECM, ABS actuator and electric unit
(control unit) judges that engine control system is malfunctioning.–
ACTUATOR RLY
[C1140] (Note 3)

Actuator solenoid valve relay is ON, even if control unit sends
off signal.

Actuator solenoid valve relay is OFF, even if control unit sends
on signal.BRC-47, "
Inspection 8:
Actuator Motor System"
DECEL G SEN SET (AWD model)
[C1160]Neutral position correction of Decel G -sensor is not finished.BRC-52, "
Inspection 13:
When “DECEL G SEN
SET” Appears on Self-
Diagnosis Results Dis-
play (AWD Model)"
Self-diagnostic item Malfunction detecting condition Check system

TROUBLE DIAGNOSIS
BRC-33
[VDC/TCS/ABS]
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Revision: 2004 November 2004 FX35/FX45
×:Applicable
–:Not applicable
Note: Serves as EBD warning lamp.
ACTIVE TEST
CAUTION:

Do not perform active test while driving.

Make sure to completely bleed air from the brake system.

Active test cannot be performed when EBD, ABS, TCS or VDC operation is malfunction.

ABS and brake warning lamps turn on during the active test.
Operation Procedure
1. Connect CONSULT-II and CONVERTER to data link connector and 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.
2. Touch “START (NISSAN BASED VHCL) ” on the display screen.
3. Touch “ABS”.
If “ABS” is not indicated, go to GI-40, "
CONSULT-II Data Link Connector (DLC) Circuit" .
4. Touch “ACTIVE TEST”.
5. The test item selection screen is displayed.
6. Touch necessary test item.
7. With the “MAIN SIGNALS” display shown in reverse, touch “START”.
8. The “ACTIVE TEST” screen will be displayed, so perform the following test.
Solenoid Valve Operation Chart
CRANKING SIG
(ON/OFF)––×Cranking condition (ON/OFF) sta-
tus is displayed.
4WD FAIL REQ
(ON/OFF)––×AWD fail-safe signal (ON/OFF)
status is displayed.
2WD/4WD
(2WD/4WD)––×Distinguish 2WD and AWD Item
(Unit)Data monitor item selection
Remarks
ECU INPUT
SIGNALSMAIN
SIGNALSSELECTION
FROM MENU
SFIA1172E
OperationABS solenoid valve ABS solenoid valve (ACT)
UP KEEP DOWN UPACTUATOR
UPACTUATOR
KEEP
FR RH IN SOL OFF ON ON OFF OFF OFF
FR RH OUT SOL OFF OFF ON* OFF OFF OFF
FR LH IN SOL OFF ON ON OFF OFF OFF
FR LH OUT SOL OFF OFF ON* OFF OFF OFF
RR RH IN SOL OFF ON ON OFF OFF OFF
RR RH OUT SOL OFF OFF ON* OFF OFF OFF