brakes INFINITI FX35 2005 Service Manual

ABCDEFGHIJKMLQUICK REFERENCE INDEX AGENERAL INFORMATIONGIGeneral InformationBENGINEEMEngine MechanicalLUEngine Lubrication SystemCOEngine Cooling SystemECEngine Control SystemFLFuel SystemEXExhaust SystemACCAccelerator Control SystemCTRANSMISSION/
TRANSAXLEATAutomatic TransmissionDDRIVELINE/AXLETFTransferPRPropeller ShaftFFDFront Final DriveRFDRear Final DriveFAXFront AxleRAXRear AxleESUSPENSIONFSUFront SuspensionRSURear SuspensionWTRoad Wheels & TiresFBRAKESBRBrake SystemPBParking Brake SystemBRCBrake Control SystemGSTEERINGPSPower Steering SystemHRESTRAINTSSBSeat BeltsSRSSupplemental Restraint System
(SRS)IBODYBLBody, Lock & Security SystemGWGlasses, Window System & Mir-
rorsRFRoofEIExterior & InteriorIPInstrument PanelSESeatJAIR CONDITIONERATCAutomatic Air ConditionerKELECTRICALSCStarting & Charging SystemLTLighting SystemDIDriver Information SystemWWWiper, Washer & HornBCSBody Control SystemLANLAN SystemAVAudio Visual, Navigation & Tele-
phone SystemACSAuto Cruise Control SystemPGPower Supply, Ground & Circuit Ele-
mentsLMAINTENANCEMAMaintenanceMINDEXIDXAlphabetical IndexEdition: August 2004
Revision: July 2005

ACS-6
[ICC]
DESCRIPTION
Revision: 2005 July 2005 FX
DESCRIPTIONPFP:00000
OutlineAKS00C8B
The Intelligent Cruise Control (ICC) system automatically maintains a selected distance from the vehicle
ahead according to that vehicle's speed, or at the set speed, if the road ahead is clear.
The ICC function has two cruise control modes and brake assist (with preview function).
VEHICLE-TO-VEHICLE DISTANCE CONTROL MODE
Vehicle-to-vehicle distance control mode, the driver can maintain the same speed as other vehicles without
the constant need to adjust the set speed as you would with a normal cruise control system.
The system is intended to enhance the operation of the vehicle when following the vehicle traveling in the
same lane and direction.
If the distance sensor detects a slower moving vehicle ahead, the system will reduce speed so that the vehicle
ahead can be followed at the selected distance.
The system automatically controls the throttle and applies the brakes (up to 25% of vehicle braking power) if
necessary.
The detection range of the sensor is approximately 390 ft (120 m) ahead.
Refer to Owner's Manual for Intelligent Cruise Control System operating instructions.
CONVENTIONAL (FIXED SPEED) CRUISE CONTROL MODE
Conventional (fixed speed) cruise control mode is cruising at preset speeds.
Refer to Owner's Manual for Intelligent Cruise Control System operating instructions.
BRAKE ASSIST (WITH PREVIEW FUNCTION)
When the force applied to brake pedal exceeds a certain level, the Brake Assist is activated and generates a
greater braking force than that of a conventional brake booster even with light pedal force.
When the Preview Function identifies the need to apply the sudden brake by sensing the vehicle ahead in the
same lane and the distance and relative speed from it, it applies the brake pre-pressure before driver depress
the brake pedal and improves brake response by reducing its free play.
Refer to Owner's Manual for BRAKE ASSIST (WITH PREVIEW FUNCTION) operating instructions.
System DiagramAKS00C8C
PKIB4142E

TERMINALS AND REFERENCE VALUE ACS-27
[ICC]
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ACS
Revision: 2005 July 2005 FX
TERMINALS AND REFERENCE VALUEPFP:00000
Terminals and Reference Value for ICC UnitAKS00C8I
Terminals
(Wire color) Item Condition
Voltage (V)
+– Ignition
switch Operation
1 (R/W)
2 (R/W)
Ground Battery power supply OFF — Battery voltage
5 (R) CAN L — — —
6 (GY/L) Release switch power supply ON — Approx. 10
7 (GY/R) NEUT-SW ON Selector lever in “N” or “P” posi-
tions Approx. 12
Selector lever in other positions Approx. 0
8 (Y/G) 24 (Y/R) Brake pressure sensor power
supply ON — Approx. 5
10 (B/R)
Ground Brake booster solenoid
(+) side ON — Approx. 12
12 (L/W) Brake booster solenoid
(–) side ON Solenoid operating
Solenoid not operating Approx. 12
14 (L) CAN H — — —
15 (LG/R) Brake release switch
(normal closed) ON Depress the brake pedal Approx. 0
Release the brake pedal Approx. 10
17 (BR) 24 (Y/R) Brake pressure sensor signal ON Release the brake pedal Approx. 0.5
Depress the brake pedal Approx. 0.5 - 3
(Note) Voltage becomes higher depending on effectiveness of
depressing brakes.
19 (B)
20 (B)
46 (B)
Ground Ground ON — Approx. 0
22 (G/Y) Brake release switch
(normally open) ON Depress the brake pedal Approx. 10
Release the brake pedal Approx. 0
29 (SB) ICC brake switch
(normal closed) ON Selector
lever: Not
in “N” or
“P” position Depress the brake
pedal Approx. 0
Release the brake
pedal Approx. 12
30 (Y) DDL - TX — — —
33 (G/R)
42 (G/R) Ignition switch ON or START ON — Battery voltage
38 (P/B) Stop lamp switch
(normally open) ON Depress the brake pedal Approx.12
Release the brake pedal Approx. 0
39(G/OR) DDL - RX — — —
PKIA9673E

TROUBLE DIAGNOSIS AT-47
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Revision: 2005 July 2005 FX
DIAGNOSTIC WORKSHEET
Information from Customer
KEY POINTS

WHAT ..... Vehicle and A/T model

WHEN ..... Date, Frequencies

WHERE ..... Road conditions

HOW..... Operating conditions, Symptoms
Diagnostic Worksheet Chart
Customer name MR/MS Model and Year VIN
Trans. Model Engine Mileage
Malfunction Date Manuf. Date In Service Date
Frequency ❏ Continuous ❏ Intermittent ( times a day)
Symptoms ❏ Vehicle does not move. ( ❏ Any position ❏ Particular position)
❏ No up-shift ( ❏ 1st → 2nd ❏ 2nd → 3rd ❏ 3rd → 4th ❏ 4th → 5th)
❏ No down-shift ( ❏ 5th → 4th ❏ 4th → 3rd ❏ 3rd → 2nd ❏ 2nd → 1st)
❏ Lock-up malfunction
❏ Shift point too high or too low.
❏ Shift shock or slip ( ❏ N → D ❏ Lock-up ❏ Any drive position)
❏ Noise or vibration
❏ No kick down
❏ No pattern select
❏ Others
()
A/T CHECK indicator lamp Blinks for about 8 seconds. ❏ Continuously lit ❏ Not lit
Malfunction indicator lamp (MIL) ❏ Continuously lit ❏ Not lit
1 ❏ Read the item on cautions concerning fail-safe and understand the customer's complaint. AT- 4 3
2 ❏
A/T fluid inspection AT- 5 2❏ Leak (Repair leak location.)
❏ Sta t e
❏ Amount
3 ❏
Stall test and line pressure test AT- 5 2
, AT-
54❏ Stall test
❏ Torque converter one-way clutch
❏ Front brake
❏ High and low reverse clutch
❏ Low coast brake
❏ Forward brake
❏ Reverse brake
❏ Forward one-way clutch ❏
1st one-way clutch
❏ 3rd one-way clutch
❏ Engine
❏ Line pressure low
❏ Except for input clutch and direct
clutch, clutches and brakes OK
❏ Line pressure inspection - Suspected part:

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
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SECTION BR
A
B
BR
Revision: 2005 July 2005 FX
BRAKE SYSTEM
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
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
On-Board Inspection ........................................... ..... 9
LEVEL CHECK ................................................ ..... 9
Drain and Refill .................................................... ..... 9
Bleeding Brake System ....................................... ... 10
BRAKE PIPING AND HOSE ................................. ....11
Hydraulic Circuit .................................................. .... 11
Removal and Installation of Front Brake Piping and
Brake Hose ......................................................... .... 11
REMOVAL ........................................................ .... 11
INSTALLATION ................................................ .... 11
Removal and Installation of Rear Brake Piping and
Brake Hose ......................................................... ... 12
REMOVAL ........................................................ ... 12
INSTALLATION ................................................ ... 12
Inspection After Installation ................................. ... 12
BRAKE MASTER CYLINDER ............................... ... 13
On-Board Inspection ........................................... ... 13 LEAK INSPECTION .........................................
... 13
Removal and Installation ..................................... ... 13
REMOVAL ........................................................ ... 13
INSTALLATION ................................................ ... 13
Components ........................................................ ... 13
Disassembly and Assembly ................................. ... 14
DISASSEMBLY ................................................ ... 14
ASSEMBLY ...................................................... ... 14
BRAKE BOOSTER ................................................ ... 15
On-Vehicle Service .............................................. ... 15
OPERATING CHECK ....................................... ... 15
AIRTIGHT CHECK ........................................... ... 15
Removal and Installation ..................................... ... 16
REMOVAL ........................................................ ... 16
INSPECTION AFTER REMOVAL .................... ... 16
INSTALLATION ................................................ ... 17
VACUUM LINES .................................................... ... 18
Removal and Installation ..................................... ... 18
Inspection ............................................................ ... 18
VISUAL INSPECTION ...................................... ... 18
CHECK VALVE INSPECTION .......................... ... 19
FRONT DISC BRAKE ............................................ ... 20
On-Vehicle Inspection .......................................... ... 20
PAD WEAR INSPECTION ................................ ... 20
Components ........................................................ ... 20
Removal and Installation of Brake Pad ............... ... 21
REMOVAL ........................................................ ... 21
INSTALLATION ................................................ ... 21
Removal and Installation of Brake Caliper Assembly ... 21
REMOVAL ........................................................ ... 21
INSTALLATION ................................................ ... 21
Disassembly and Assembly of Brake Caliper
Assembly ............................................................. ... 22
DISASSEMBLY ................................................ ... 22
CALIPER INSPECTION ................................... ... 23
ASSEMBLY ...................................................... ... 23
DISC ROTOR INSPECTION ............................ ... 24
BRAKE BURNISHING PROCEDURE .............. ... 25
REAR DISC BRAKE .............................................. ... 26

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION BRC
A
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BRC
Revision: 2005 July 2005 FX
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 Circuit ..................... ... 37
Inspection 2: Engine System ............................... ... 39
Inspection 3: VDC/TCS/ABS Control Unit Circuit ... 40
Inspection 4: Pressure Sensor Circuit ................. ... 40
Inspection 5: Steering Angle Sensor Circuit ........ ... 42
Inspection 6: Yaw Rate/Side G Sensor (2WD
Model), Yaw Rate/Side/Decel G sensor (AWD Mod-
els) Circuit ............................................................ ... 44
Inspection 7: Solenoid and VDC Change-Over
Valve Circuit ......................................................... ... 46
Inspection 8: Actuator Motor Circuit .................... ... 47
Inspection 9: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ......... ... 48
Inspection 10: Stop Lamp Switch Circuit ............. ... 50
Inspection 11: Brake Fluid Level Switch Circuit ... ... 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-diagnostic Results Display (AWD Model) ... 52
Inspection 14: CAN Communication Circuit ........ ... 53
Component Inspection ......................................... ... 53
VDC OFF SWITCH .......................................... ... 53
Symptom 1: Excessive ABS Function Operation

BRC-4
[VDC/TCS/ABS]
PRECAUTIONS
Revision: 2005 July 2005 FX

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.

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, bushing, 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 OFF
SW ON) may cause the G sensor system indicate a malfunction. However, this is not a malfunction, if nor-
mal operation can be resumed after restarting engine.

TROUBLE DIAGNOSIS BRC-35
[VDC/TCS/ABS]
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Revision: 2005 July 2005 FX
For Fast and Accurate DiagnosisAFS001SR
PRECAUTIONS FOR DIAGNOSIS

Before performing diagnosis, always read precautions. Refer to BRC-12, "How to Proceed with Diagno-
sis" .

If ABS actuator and electric unit (control unit), steering angle sensor, steering system parts or suspension
system parts have been replaced, or if alignment has been adjusted, be sure to adjust neutral position of
steering angle sensor before driving. Refer to BRC-6, "
Adjustment of Steering Angle Sensor Neutral Posi-
tion" .

After diagnosis is finished, be sure to erase memory. Refer to BRC-27, "SELF-DIAGNOSIS" .

When checking continuity and voltage between units, be sure to check for disconnection, looseness,
bend, or collapse of connector terminals. If any malfunction is found, repair or replace connector termi-
nals.

For intermittent symptoms, possible cause is malfunction in harness, harness connector, or terminals.
Move harness, harness connector, and terminals to check for poor connections.

If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal.

To use CONSULT-II to perform self-diagnosis of ABS actuator and electric unit (control unit), active tests,
or work support, first stop work, then connect CONSULT-II and select “ABS”.

While self-diagnostic results of CONSULT-II shows malfunction, if CONSULT-II active test is performed,
an engine system error may be indicated. In this case, start engine to resume the normal screen.

VDC/TCS/ABS system electronically controls brake operation and engine output. The following symptoms
may be caused by normal operations:
Symptom Symptom description Result
Motor operation noise This is noise of motor inside ABS actuator and electric unit (control unit).
Slight noise may occur during VDC, TCS, and ABS operation.
Normal
When the vehicle speed goes over 20 km/h (12.5 MPH), motor and
valves operating noise may be heard. It happens only once after IGN
(ignition) is ON. This is a normal status of the system operation check.
System operation check
noise When engine starts, slight “click” noise may be heard from engine room.
This is normal and is part of system operation check. Normal
VDC/TCS operation
(SLIP indicator lamp blink-
ing) TCS may activate momentarily if wheel speed changes when driving
over location where friction coefficient varies, when up/downshifting, or
when fully depressing accelerator pedal.
Normal
Cancel the VDC/TCS
function for the
inspection on a chas-
sis dynamometer.
For inspection of speedometer or other instruments, press
VDC OFF SW to turn VDC/TCS function off.
When accelerator pedal is depressed on a chassis dynamometer (fixed
front-wheel type), vehicle speed will not increase. This is not normal. It is
result of TCS being activated by stationary front wheels. Warning lamp
may also illuminate to indicate “sensor system error”. This is also nor-
mal, and is the result of the stationary front wheels being detected. To be
certain, restart engine, and drive vehicle at 30 km/h (19 MPH) or more.
Make sure warning lamp does not illuminate.
ABS operation (Longer stop-
ping distance) On roads with low friction coefficients, such as snowy roads or gravel
roads, vehicles with ABS may require a longer stopping distance. There-
fore, when driving on such roads, avoid overconfidence and keep speed
sufficiently low. Normal
Insufficient feeling of accel-
eration Depending on road conditions, driver may feel that feeling of accelera-
tion is insufficient. This is because traction control, which controls
engine and brakes to achieve optimal traction, has the highest priority
(for safety). As a result, there may be times when acceleration is slightly
less than usual for the same accelerator pedal operation. Normal

CO-8
[VQ35DE]
OVERHEATING CAUSE ANALYSIS
Revision: 2005 July 2005 FX
Except cool-
ing system
parts mal-
function — Overload on engine
Abusive driving
High engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
—
Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flow Blocked bumper —
—
Blocked radiator grille
Installed car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser Blocked air flow
Installed large fog lamp
Symptom Check items

CO-34
[VK45DE]
OVERHEATING CAUSE ANALYSIS
Revision: 2005 July 2005 FX
Except cool-
ing system
parts mal-
function — Overload on engine
Abusive driving
High engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
—
Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flow Blocked bumper —
—
Blocked radiator grille
Installed car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser Blocked air flow
Installed large fog lamp
Symptom Check items