Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti I35 A33 2002-2004 Approved Infiniti I35 2002 br
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BRAKE SYSTEM
GI
SECTION BR MA
EM
LC
EC
CONTENTS
FE
PRECAUTIONS ...............................................................4 OPERATING CHECK ...............................................20
Supplemental Restraint System (SRS) AIR AIRTIGHT CHECK ...................................................20 AT
BAG and SEAT BELT PRE-TENSIONER...............4 Removal.....................................................................20
Precautions for Brake System.....................................4 Inspection...................................................................20
Wiring Diagrams and Trouble Diagnosis.....................5 OUTPUT ROD LENGTH CHECK ..............................20 AX
PREPARATION ...............................................................6 Installation..................................................................20
Commercial Service Tools ...........................................6 VACUUM HOSE.............................................................22
Removal and Installation ...........................................22 SU
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................7 Inspection...................................................................22
NVH Troubleshooting Chart.........................................7 HOSES AND CONNECTORS ...................................22
CHECK VALVE ........................................................22
ON-VEHICLE SERVICE ..................................................8
FRONT DISC BRAKE ...................................................23
Checking Brake Fluid Level.........................................8
Component ................................................................23 ST
Checking Brake Line ...................................................8
Pad Replacement ......................................................23
Changing Brake Fluid ..................................................8
Removal.....................................................................24
Brake Burnishing Procedure........................................8
Bleeding Brake System ...............................................9
Disassembly...............................................................24 RS
Inspection...................................................................25
BRAKE HYDRAULIC LINE ...........................................10
CALIPER .................................................................25
Hydraulic Circuit.........................................................10 BT
ROTOR ...................................................................25
Removal.....................................................................10
Assembly ...................................................................26
Inspection...................................................................10
Installation..................................................................26
Installation..................................................................11
REAR DISC BRAKE......................................................27
HA
BRAKE PEDAL AND BRACKET..................................12
Component ................................................................27
Removal and Installation ...........................................12
Pad Replacement ......................................................27 SC
Inspection...................................................................12
Removal.....................................................................29
Adjustment .................................................................12
Disassembly...............................................................30
MASTER CYLINDER (TOKICO) ...................................14 EL
Inspection...................................................................31
Removal.....................................................................14
CALIPER .................................................................31
Disassembly...............................................................15 ROTOR ...................................................................31
Inspection...................................................................15 Assembly ...................................................................32 IDX
Assembly ...................................................................15 Installation..................................................................34
Installation..................................................................16 PARKING BRAKE CONTROL ......................................35
MASTER CYLINDER [BOSCH (NABCO)] ...................17 Components...............................................................35
Removal.....................................................................17 Removal and Installation ...........................................35
Disassembly...............................................................18 Inspection...................................................................35
Inspection...................................................................18 Adjustment .................................................................36
Assembly ...................................................................18
Installation..................................................................19
TCS
BRAKE BOOSTER........................................................20
On-vehicle Service.....................................................20 DESCRIPTION ...............................................................37
CONTENTS (Cont'd)
Purpose......................................................................37 INSPECTION PROCEDURE .....................................74
ABS (Anti-Lock Brake System) Operation ................37 Engine System...........................................................74
ABS Hydraulic Circuit ................................................37 DIAGNOSTIC PROCEDURE .....................................74
TCS (Traction Control System) Operation ................38 A/T System ................................................................75
System Components .................................................38 DIAGNOSTIC PROCEDURE .....................................75
System Description....................................................39 TROUBLE DIAGNOSES FOR SYMPTOMS .................76
SENSOR .................................................................39 1. ABS Works Frequently ..........................................76
CONTROL UNIT ......................................................39 2. Unexpected Pedal Action ......................................76
ACTUATOR .............................................................39 3. Long Stopping Distance ........................................77
Component Parts and Harness Connector 4. ABS Does Not Work..............................................78
Location .....................................................................41 5. Pedal Vibration and Noise.....................................79
Schematic ..................................................................42 6. ABS Warning Lamp Does Not Come On
Wiring Diagram - TCS -.............................................43 When Ignition Switch Is Turned On...........................80
ON BOARD DIAGNOSTIC SYSTEM 7. ABS Warning Lamp Stays On When Ignition
DESCRIPTION ...............................................................47 Switch Is Turned On ..................................................81
CONSULT-II Functions ..............................................47 8. SLIP Indicator Lamp Does Not Come On
CONSULT-II MAIN FUNCTION ..................................47 When Ignition Switch Is Turned On...........................83
ECU (ABS/TCS CONTROL UNIT) PART NUMBER 9. TCS OFF Indicator Lamp Does Not Come On
MODE .....................................................................47 When Ignition Switch Is Turned On...........................84
CONSULT-II Inspection Procedure............................47 10. TCS OFF Switch Is Inoperative ..........................86
SELF-DIAGNOSIS PROCEDURE ..............................47 11. Poor Acceleration.................................................89
SELF-DIAGNOSTIC RESULTS MODE.......................49
ABS ACTUATOR AND ELECTRIC UNIT.....................90
DATA MONITOR PROCEDURE ................................50
Removal.....................................................................90
ACTIVE TEST PROCEDURE ....................................51
Installation..................................................................90
DATA MONITOR MODE ...........................................52
ACTIVE TEST MODE ...............................................53
TROUBLE DIAGNOSIS - INTRODUCTION..................54 VDC
How to Perform Trouble Diagnoses for Quick PRECAUTIONS .............................................................91
and Accurate Repair ..................................................54 Supplemental Restraint System (SRS) AIR
INTRODUCTION ......................................................54
BAG and SEAT BELT PRE-TENSIONER.............91
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........55
Precautions for Brake System...................................91
Preliminary Check......................................................55
Precautions for Brake Control ...................................92
Ground Circuit Check ................................................58
Precautions for CAN System.....................................92
ABS ACTUATOR AND ELECTRIC UNIT GROUND.....58
FOR INSPECTION ...................................................92
TROUBLE DIAGNOSIS - GENERAL
FOR HARNESS REPAIR ..........................................92
DESCRIPTION ...............................................................59 ON-VEHICLE SERVICE ................................................94
Malfunction Code/Symptom Chart.............................59 Adjustment of Neutral Position of Steering Angle
CAN COMMUNICATION ...............................................61 Sensor........................................................................94
System Description....................................................61 GENERAL INFORMATION ...........................................96
FOR TCS MODELS .................................................61
Fail-safe .....................................................................96
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ABS SYSTEM ..........................................................96
ITEMS.............................................................................62 VDC/TCS SYSTEM ..................................................96
Wheel Sensor or Rotor..............................................62 Hydraulic Circuit.........................................................97
DIAGNOSTIC PROCEDURE .....................................62 ABS Functions ...........................................................97
ABS Actuator Solenoid Valve or Solenoid Valve TCS Functions ...........................................................98
Relay..........................................................................66 VDC Functions...........................................................98
DIAGNOSTIC PROCEDURE .....................................66
System Diagram ........................................................99
Motor Relay or Motor.................................................69
CAN COMMUNICATION .............................................100
DIAGNOSTIC PROCEDURE .....................................69
System Description..................................................100
Low Voltage ...............................................................71
FOR VDC MODELS ...............................................100
DIAGNOSTIC PROCEDURE .....................................71
TROUBLE DIAGNOSIS - INTRODUCTION................101
Control Unit................................................................73
How to Perform Trouble Diagnoses for Quick
DIAGNOSTIC PROCEDURE .....................................73
and Accurate Repair ................................................101
CAN Communication System ....................................74
BR-2
CONTENTS (Cont'd)
INTRODUCTION ....................................................101 Inspection 14 Brake Fluid Level of Reservoir
WORK FLOW ........................................................102 Tank .........................................................................156
ASKING COMPLAINTS ..........................................103 Inspection 15 CAN Communication System, GI
EXAMPLE OF DIAGNOSIS SHEET .........................103 VDC/TCS/ABS Control Unit and Steering Angle
Component Parts and Harness Connector Sensor......................................................................157
Location ...................................................................104 MA
Component Check ...................................................158
Schmatic ..................................................................105 VDC OFF SWITCH ................................................158
Wiring Diagram -VDC/TCS/ABS- ............................106 VDC/TCS/ABS RELAY BOX ...................................158 EM
Control Unit Input/Output Signal Standard..............114 VDC/TCS/ABS ACTUATOR ....................................159
STANDARDS USING A CIRCUIT TESTER AND TROUBLE DIAGNOSES FOR SYMPTOMS ...............162
OSCILLOSCOPE ...................................................114 Symptom 1: ABS Works Frequently........................162 LC
STANDARDS WITH CONSULT-II ............................117 Symptom 2: Unexpected Pedal Action....................162
CONSULT-II Functions ............................................119 Symptom 3: Longer Stopping Distance...................163
CONSULT-II MAIN FUNCTION ................................119
Symptom 4: ABS Does Not Work ...........................164 EC
SELF-DIAGNOSIS .................................................120
Symptom 5: Pedal Vibration and Noise ..................164
DATA MONITOR....................................................124
Symptom 6: VDC OFF Indicator Lamp Does Not
ACTIVE TEST ........................................................126 FE
For Correct and Quick Diagnosis ............................130 Illuminate..................................................................165
PRECAUTIONS FOR TROUBLE DIAGNOSIS ..........130 Symptom 7: SLIP Indicator Lamp Does Not
TROUBLE DIAGNOSIS - BASIC INSPECTION .........132 Illuminate..................................................................166 AT
Preliminary Check 1: (Brake Fluid Level and Symptom 8: During VDC/TCS/ABS Control,
Leak Inspection) ......................................................132 Vehicle Behavior is Jerky ........................................166
Preliminary Check 2: (Inspection for Loose VDC/TCS/ABS CONTROL UNIT.................................168 AX
Power Supply Terminal)...........................................132 Removal and Installation .........................................168
Preliminary Check 3: (Inspection for ABS REMOVAL .............................................................168
INSTALLATION......................................................168
SU
Warning Lamp, VDC OFF Indicator Lamp, and
VDC/TCS/ABS ACTUATOR AND RELAY BOX ........169
SLIP Indicator Lamp)...............................................132
Removal and Installation .........................................169
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
YAW RATE/SIDE G SENSOR.....................................170
ITEMS...........................................................................134
Removal and Installation .........................................170
Inspection 1 Wheel Speed Sensor and Circuit .......134
Inspection 2 Engine System....................................136
REMOVAL .............................................................170 ST
INSTALLATION......................................................170
Inspection 3 VDC/TCS/ABS Control Unit System...137
VDC OFF SWITCH ......................................................171
Inspection 4 Pressure Sensor and The Circuit RS
Removal and Installation .........................................171
Between Pressure Sensor and VDC/TCS/ABS REMOVAL .............................................................171
Control Unit..............................................................138 INSTALLATION......................................................171
Inspection 5 Steering Angle Sensor and The BT
Circuit Between Steering Angle Sensor and TCS/VDC
VDC/TCS/ABS .........................................................140
Inspection 6 Yaw Rate/Side G and The Circuit REMOVAL AND INSTALLATION ...............................172 HA
Between Yaw Rate/Side G and VDC/TCS/ABS Wheel Sensors ........................................................172
Control Unit..............................................................142 Sensor Rotor............................................................172
REMOVAL .............................................................172
SC
Inspection 7 Solenoid Valve, VDC Switch-over
Solenoid Valve and Circuit ......................................143 INSTALLATION......................................................173
Inspection 8 Actuator Motor, Motor Relay and EL
Circuit.......................................................................147 SERVICE DATA AND SPECIFICATIONS (SDS) .......174
Inspection 9 Actuator Relay and Circuit ..................149 General Specifications.............................................174
Inspection 10 Stop Lamp Switch and Circuit ..........151 Disc Brake ...............................................................174 IDX
Inspection 11 VDC/TCS/ABS Control Unit Power Brake Pedal .............................................................174
Supply Circuit...........................................................152 Parking Brake ..........................................................174
Inspection 12 When EMERGENCY BRAKE Is Brake Booster ..........................................................174
Indicated in The Self-diagnosis Results ..................155 ABS Wheel Sensor..................................................174
Inspection 13 When ST ANG SEN SIGNAL is
Indicated in The Self-diagnosis Results ..................155
BR-3
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" NHBR0127
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER" used along with
a 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. The SRS
system composition which is available to INFINITI I35 is as follows:
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