brakes NISSAN X-TRAIL 2003 Service Owner's Manual

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION
A
B
BRC

BRAKE CONTROL SYSTEM
ABS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Brake System .................................. 4
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
SYSTEM DESCRIPTION ............................................ 6
System Diagram ....................................................... 6
ABS Function ........................................................... 6
EBD Function ........................................................... 6
Fail-Safe Function .................................................... 6
ABS, EBD SYSTEM .............................................. 6
Hydraulic Circuit Diagram ........................................ 7
CAN COMMUNICATION ............................................ 8
System Description .................................................. 8
CAN Communication Unit ........................................ 8
TYPE 1 .................................................................. 8
TYPE 2 .................................................................. 9
TROUBLE DIAGNOSIS .............................................11
How to Proceed With Diagnosis .............................. 11
BASIC CONCEPT ................................................ 11
DIAGNOSIS FLOWCHART ................................ 12
ASKING COMPLAINTS ...................................... 13
EXAMPLE OF DIAGNOSIS SHEET ................... 13
Component Parts Location ..................................... 14
Schematic .............................................................. 15
Wiring Diagram — ABS — ..................................... 16
Control Unit Input/Output Signal Standard ............. 24
REFERENCE VALUE FROM CONSULT-II ......... 24
CONSULT- II Functions .......................................... 25
CONSULT-II MAIN FUNCTION ........................... 25
CONSULT-II BASIC OPERATION PROCEDURE
... 25
SELF-DIAGNOSIS .............................................. 27
DATA MONITOR ................................................. 29
ACTIVE TEST ..................................................... 31
Correct and Quick Diagnosis ................................. 33DIAGNOSIS PRECAUTIONS ............................. 33
Basic Inspection ..................................................... 34
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 34
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 34
BASIC INSPECTION 3 ABS WARNING LAMP ... 34
Inspection 1: Wheel Sensor System ....................... 35
INSPECTION PROCEDURE .............................. 35
Inspection 2: ABS Actuator and Electric Unit (Con-
trol Unit) 1 ............................................................... 37
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 37
Inspection 4: ABS Actuator Relay or ABS Motor
Relay Power System .............................................. 38
Inspection 5: ABS Actuator and Electric Unit (Con-
trol Unit) 2 ............................................................... 39
Inspection 6: G Sensor System .............................. 40
Inspection 7: CAN Communication System ............ 42
Symptom 1: ABS Works Frequently ....................... 42
Symptom 2: Unexpected Pedal Reaction ............... 43
Symptom 3: Longer Stopping Distance .................. 43
Symptom 4: ABS Does Not Work ........................... 44
Symptom 5: Pedal Vibration and ABS Operation
Noise ...................................................................... 44
WHEEL SENSORS ................................................... 45
Removal and Installation ........................................ 45
REMOVAL ........................................................... 45
INSTALLATION ................................................... 45
G SENSOR ................................................................ 46
Removal and Installation ........................................ 46
SENSOR ROTOR ..................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSTALLATION ................................................... 47
ABS ACTUATOR AND ELECTRIC UNIT (ASSEM-
BLY) ........................................................................... 48
Removal and Installation ........................................ 48

PRECAUTIONS
BRC-49
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC

[ESP/TCS/ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS004H7
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. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
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 SystemEFS0019O

Recommended fluid is brake fluid “DOT 3” or “DOT 4”.

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.

Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system.

Use a flare nut wrench when removing and installing brake
tubes.

When installing brake piping, be sure to check torque.

Before working, turn the ignition switch OFF and disconnect the
connectors for the ESP actuator and control unit or the battery
negative terminal.

Burnish the brake pad contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings, or if a
soft pedal occurs at very low mileage. Refer to BR-31, "
BRAKE
BURNISHING PROCEDURE" .
WARNING:
Clean brakes with a vacuum dust collector to minimize risk of health hazard from powder caused
by friction.
Precautions for Brake ControlEFS0019P

During the ESP/TCS/ABS operation, the brake pedal vibrates lightly and its mechanical noise may be
heard. This is a normal condition.

Just after starting the vehicle after ignition switch ON, the brake pedal may vibrate or the motor operating
noise may be heard from the engine compartment. This is a normal status of the operation check.

The stopping distance may be longer than that of vehicles without ABS when the vehicle drives on rough,
gravel, or snowy (fresh deep snow) road.

If a malfunction is indicated by the ABS warning lamp, or other warning lamps, collect the necessary infor-
mation from the customer (what symptoms are present under what conditions) and find out the possible
causes before starting the service. Besides the electrical system inspection, check the booster operation,
brake fluid level, and oil leaks.

If the tyre size and type are used in a improper combination, or the brake pads are not NISSAN genuine
parts, the stopping distance or steering stability may deteriorate.

If there is a radio, antenna, or antenna lead-in wire (including wiring) near the control unit, the ESP/TCS/
ABS function may have a malfunction or error.

If aftermarket parts (e.g. Car stereo equipment, CD player) have been installed, check harnesses for
pinches, open, and improper wiring.
SBR820BA

BRC-86
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS

For Fast and Accurate DiagnosisEFS004H8
PRECAUTIONS FOR DIAGNOSIS

Before performing diagnosis, always read precautions. Refer to BRC-58, "How to Proceed With Diagno-
sis" .

If ESP/TCS/ABS 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-51, "
Adjustment of Steering Angle Sensor Neutral Position" .

After diagnosis is finished, be sure to erase memory. Refer to BRC-79, "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 ESP/TCS/ABS 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.

ESP/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 noiseThis is noise of motor inside ESP/TCS/ABS control unit. Slight noise
may occur during ESP, 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
noiseWhen engine starts, slight “click” noise may be heard from engine room.
This is normal and is part of system operation check.Normal
ESP/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 ESP/TCS
function for the
inspection on a chas-
sis dynamometer. For inspection of speedometer or other instruments, press ESP OFF
SW to turn ESP/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-
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

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PS-5
C
D
E
F
H
I
J
K
L
MA
B
PS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Trouble shooting ChartEGS000A9
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
PS-6PS-6PS-17PS-17PS-17PS-6PS-7–
EM-13
.
–
PS-12
–
PS-10PS-10PS-13
NVH in PR section
NVH in RFD section
NVH in FAX, RAX, FSU, RSU section
NVH in WT section
NVH in WT section
NVH in RAX section
NVH in BR section
Possible cause and SUSPECTED PARTS
Fluid level
Air in hydraulic system
Tie-rod ball joint swinging force
Tie-rod ball joint rotating torque
Tie-rod ball joint end play
Steering gear fluid leakage
Steering wheel play
Steering gear rack sliding force
Drive belt looseness
Improper steering wheel
Improper installation or looseness or tilt lock lever
Mounting rubber deterioration
Steering column deformation or damage
Improper installation or looseness of steering column
Steering linkage looseness
PROPELLER SHAFT
DIFFERENTIAL
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
Symptom STEERINGNoise× × ××××× × × ×××××× ×
Shake××× × ×××× ×
Vibration××××× × ×× ×
Shimmy××× × ××× ×
Judder× × ××× ×

DESCRIPTION
MA-5
C
D
E
F
G
H
I
J
K
MA
B
MA

ROAD TEST
Check clutch operation
Check foot brake operation
Check parking brake operation
Check steering operation, self-centering and steering wheel alignment
Check engine performance
Check for squeaks, rattles and noise from interior, suspension and brakes
Check heating, ventilation and air conditioning operation
Check radio, cassette and CD player operation
Check odometer and trip meter operation and cancelling
Check instruments for operation
Check automatic transmission/transaxle shift pattern and kickdown operation (if applicable)
Check cruise control and navigation system operation (if applicable)
ENGINE OPERATING AND HOT
Check idle speed
Check automatic transmission/transaxle oil level (if applicable)
FINAL INSPECTION
Remove vehicle protection kit
Fit interior mats and wheel covers
Check for interior and exterior metal and paint damage
Wash, clean interior and exterior
: Not applicable to this model