brakes INFINITI M35 2006 Factory Service Manual

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QUICK REFERENCE INDEX
AGENERAL INFORMATIONGIGeneral Information
BENGINEEMEngine Mechanical
LUEngine Lubrication System
COEngine Cooling System
ECEngine Control System
FLFuel System
EXExhaust System
ACCAccelerator Control System
CTRANSMISSION/
TRANSAXLEATAutomatic Transmission
DDRIVELINE/AXLETFTransfer
PRPropeller Shaft
FFDFront Final Drive
RFDRear Final Drive
FAXFront Axle
RAXRear Axle
ESUSPENSIONFSUFront Suspension
RSURear Suspension
WTRoad Wheels & Tires
FBRAKESBRBrake System
PBParking Brake System
BRCBrake Control System
GSTEERINGPSPower Steering System
STCSteering Control System
HRESTRAINTSSBSeat Belts
SRSSupplemental Restraint System
(SRS)
IBODYBLBody, Lock & Security System
GWGlasses, Window System & Mir-
rors
RFRoof
EIExterior & Interior
IPInstrument Panel
SESeat
JAIR CONDITIONERATCAutomatic Air Conditioner
KELECTRICALSCStarting & Charging System
LTLighting System
DIDriver Information System
WWWiper, Washer & Horn
BCSBody Control System
LANLAN System
AVAudio-Visual System
ACSAuto Cruise Control System
PGPower Supply, Ground & Circuit Ele-
ments
LMAINTENANCEMAMaintenance
MINDEXIDXAlphabetical Index
Edition: January 2005
Revision: January 2006

ACS-6
[ICC]
DESCRIPTION
Revision: 2006 January2006 M35/M45
DESCRIPTIONPFP:00000
OutlineNKS004CF
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 the driver 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 ICC sensor integrated unit 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
depresses 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 DiagramNKS004CG
PKIB8345E

AT-48
TROUBLE DIAGNOSIS
Revision: 2006 January2006 M35/M45
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 N R Lock-up Any drive position)
Noise or vibration
No kick down
No pattern select
Others
()
A/T CHECK indicator lamp
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 4
2
A/T fluid inspectionAT- 5 3
Leak (Repair leak location.)
State
Amount
3
Stall test and line pressure testAT- 5 3, AT-
55 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: 2006 January2006 M35/M45
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
ADJUSTMENT ...................................................... 7
Removal and Installation .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ........................................................
..... 8
INSPECTION AFTER REMOVAL ......................... 8
INSTALLATION ..................................................... 9
BRAKE FLUID .......................................................... 10
On-Board Inspection .............................................. 10
CHECKING BRAKE FLUID LEVEL .................... 10
Checking Brake Line .............................................. 10
Drain and Refill ....................................................... 10
Bleeding Brake System ........................................... 11
BRAKE TUBE AND HOSE ....................................... 12
Hydraulic Circuit ..................................................... 12
Removal and Installation of Front Brake Tube and
Brake Hose ............................................................ 13
REMOVAL ........................................................
... 13
INSTALLATION ................................................... 13
Removal and Installation of Rear Brake Tube and
Brake Hose ............................................................ 13
REMOVAL ........................................................
... 13
INSTALLATION ................................................... 14
Inspection after Installation .................................... 14
BRAKE MASTER CYLINDER .................................. 15
On-Board Inspection .............................................. 15
LEAK INSPECTION ............................................ 15
Removal and Installation ........................................ 15REMOVAL ........................................................
... 15
INSTALLATION ................................................... 15
Disassembly and Assembly .................................... 16
COMPONENTS ................................................... 16
Disassembly and Assembly .................................... 16
DISASSEMBLY ................................................... 16
ASSEMBLY ......................................................... 17
BRAKE BOOSTER ................................................... 18
On-Board Inspection and Service ........................... 18
OPERATION CHECK .......................................... 18
AIR TIGHT CHECK ............................................. 18
Removal and Installation ........................................ 19
COMPONENTS ................................................... 19
REMOVAL ........................................................
... 19
INSTALLATION ................................................... 19
VACUUM LINES ....................................................... 21
Components ........................................................... 21
Removal and Installation ........................................ 22
Inspection ............................................................... 22
VISUAL INSPECTION ......................................... 22
CHECK VALVE INSPECTION ............................. 22
FRONT DISC BRAKE ............................................... 23
On-Board Inspection ............................................
... 23
PAD WEAR INSPECTION ................................... 23
Components ........................................................... 23
Removal and Installation of Brake Pad .................. 24
REMOVAL ........................................................
... 24
INSTALLATION ................................................... 24
Removal and Installation of Brake Caliper Assembly
... 25
REMOVAL ........................................................
... 25
INSTALLATION ................................................... 25
Disassembly and Assembly of Brake Caliper
Assembly ................................................................ 26
DISASSEMBLY ................................................... 26
INSPECTION AFTER DISASSEMBLY ................ 26
ASSEMBLY ......................................................... 27
DISC ROTOR INSPECTION ............................... 28
BRAKE BURNISHING PROCEDURE ................. 28
REAR DISC BRAKE ................................................. 29

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
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SECTION BRC
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BRC
Revision: 2006 January2006 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
Function ................................................................... 7
ABS ....................................................................... 7
EBD ....................................................................... 7
TCS ....................................................................... 7
VDC ....................................................................... 8
ECD ....................................................................... 8
Operation That Is Not "System Error" ...................... 8
ABS ....................................................................... 8
TCS ....................................................................... 8
VDC ....................................................................... 8
Fail-Safe Function .................................................... 8
ABS, EBD SYSTEM .............................................. 8
VDC / TCS ............................................................ 9
Hydraulic Circuit Diagram ........................................ 9
CAN COMMUNICATION .......................................... 10
System Description ................................................ 10
TROUBLE DIAGNOSIS .............................................11
How to Perform Trouble Diagnoses ........................ 11
BASIC CONCEPT ................................................ 11
DIAGNOSIS FLOW CHART ............................... 12
ASKING COMPLAINTS ...................................... 13
EXAMPLE OF DIAGNOSIS WORKSHEET ........ 13
Component Parts Location ..................................... 14
Schematic .............................................................. 15Wiring Diagram — VDC — ..................................... 16
CONSULT-II Functions (ABS) ................................ 22
CONSULT-II MAIN FUNCTION ........................... 22
CONSULT-II BASIC OPERATION PROCEDURE
... 22
Self-Diagnosis .....................................................
... 23
OPERATION PROCEDURE ................................ 23
ERASE MEMORY ............................................... 23
DISPLAY ITEM LIST ........................................... 24
Data Monitor ........................................................... 27
OPERATION PROCEDURE ................................ 27
DISPLAY ITEM LIST ........................................... 27
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
Inspection 1: Wheel Sensor Circuit ........................ 34
Inspection 2: Engine System .................................. 36
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) .................................................................. 36
Inspection 4: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 37
Inspection 5: ABS Motor and Motor Relay Circuit ... 38
Inspection 6: Solenoid, VDC Change-Over Valve
and Actuator Relay Circuit ...................................... 40
Inspection 7: Pressure Sensor Circuit .................... 41
Inspection 8: Steering Angle Sensor Circuit ........... 41
Inspection 9: Park/Neutral Position (PNP) Switch
Circuit ..................................................................... 43
Inspection 10: Stop Lamp Switch Circuit ................ 44
Inspection 11: Yaw Rate/Side G Sensor Circuit ..... 45

BRC-32
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2006 January2006 M35/M45
For Fast and Accurate DiagnosisNFS000QJ
PRECAUTIONS FOR DIAGNOSIS
Before performing diagnosis, always read General Information (GI) to confirm general precautions. Refer
to GI-4, "
General Precautions" .
If steering angle sensor, steering system parts, suspension system parts, ABS actuator and electric unit
(control unit) or tires have been replaced, or if wheel alignment has been adjusted, be sure to adjust neu-
tral position of steering angle sensor before driving. Refer to BRC-6, "
Adjustment of Steering Angle Sen-
sor Neutral Position" .
After diagnosis is finished, be sure to erase memory. Refer to BRC-23, "ERASE MEMORY" .
When checking continuity and voltage between unit, be sure to check for disconnection, looseness, bend,
or collapse of connector terminals. If any malfunction is found, repair or replace connector terminals.
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.
The following symptoms may be caused by normal operations.
Symptom Symptom description Result
Motor operation soundThis is sound of motor inside VDC actuator. Slight sound may occur
during VDC, TCS, and ABS operation.
Normal
Just after engine starts, the motor operating sound may be heard. This
is a normal condition of the system operation check.
System operation check
soundWhen engine starts, slight “click” sound may be heard from engine
room. This is normal and is part of system operation check.Normal
VDC/TCS operation
(SLIP indicator lamp ON)TCS may activate momentarily if wheel speed changes when driving
over location where friction varies, when downshifting, or when fully
depressing accelerator pedal.Normal
Cancel the VDC/TCS
function for the
inspection on a chas-
sis dynamometer. When checking speed meter etc. with a 2-wheel-drive chassis dyna-
mometer, vehicle speed is not increased by pressing down on the accel-
erator.
ABS operation (Longer stop-
ping distance)On roads with low friction, such as snowy roads or gravel roads, vehi-
cles with ABS may require a longer stopping distance. Therefore, when
driving on such roads, avoid overconfidence and keep speed sufficiently
low.Normal
Insufficient feeling of accel-
erationDepending 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: 2006 January2006 M35/M45
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh 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
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items

OVERHEATING CAUSE ANALYSIS
CO-37
[VK45DE]
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CO
Revision: 2006 January2006 M35/M45
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh 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
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items

FAX-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2006 January2006 M35/M45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNDS000FE
Use chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
: ApplicableReference page
—
FA X - 1 4—
FAX-5—
FAX-5
NVH in FAX and FSU sections
Refer to Front axle in this chart.
NVH in WT section
NVH in WT section
Refer to DRIVE SHAFT in this chart.
NVH in BR section
NVH in PS section
Possible cause and SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
Wheel bearing damage
FRONT AXLE AND FRONT SUSPENSION
FRONT AXLE
TIRES
ROAD WHEELS
DRIVE SHAFT
BRAKES
STEERING
SymptomDRIVE
SHAFTNoise
Shake
FRONT
AXLENoise
Shake
Vibration
Shimmy
Judder
Poor quality ride or handling

FFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2006 January2006 M35/M45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNDS000EO
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
: ApplicableReference page
Refer to FFD-24, "
INSPECTION AFTER DISASSEMBLY
" .
Refer to FFD-17, "
Tooth Contact
" .
Refer to FFD-24, "
INSPECTION AFTER DISASSEMBLY
" .
Refer to FFD-19, "
Backlash
" .
Refer to FFD-19, "
Companion Flange Runout
" .
Refer to FFD-8, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX and RAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise