Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Maxima 2000-2005 Approved Nissan Maxima 2000 br
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BRAKE SYSTEM
SECTION BR
CONTENTS
PRECAUTIONS ...............................................................3 Installation..................................................................18
Supplemental Restraint System (SRS) AIR Removal.....................................................................19
BAG and SEAT BELT PRE-TENSIONER...............3 Disassembly...............................................................20
Precautions for Brake System.....................................3 Inspection...................................................................20
Wiring Diagrams and Trouble Diagnosis.....................4 Assembly ...................................................................20
PREPARATION ...............................................................5 Installation..................................................................21
Commercial Service Tools ...........................................5 BRAKE BOOSTER........................................................22
NOISE, VIBRATION AND HARSHNESS (NVH) On-vehicle Service.....................................................22
TROUBLESHOOTING .....................................................6 OPERATING CHECK ...............................................22
NVH Troubleshooting Chart.........................................6 AIRTIGHT CHECK ...................................................22
ON-VEHICLE SERVICE ..................................................7 Removal.....................................................................22
Checking Brake Fluid Level.........................................7 Inspection...................................................................22
Checking Brake Line ...................................................7 OUTPUT ROD LENGTH CHECK ..............................22
Changing Brake Fluid ..................................................7 Installation..................................................................23
Brake Burnishing Procedure........................................7 VACUUM HOSE.............................................................24
Bleeding Brake System ...............................................8 Removal and Installation ...........................................24
BRAKE HYDRAULIC LINE .............................................9 Inspection...................................................................24
Hydraulic Circuit...........................................................9 HOSES AND CONNECTORS ...................................24
CHECK VALVE ........................................................24
Removal.......................................................................9
FRONT DISC BRAKE ...................................................25
Inspection.....................................................................9
Component ................................................................25
Installation..................................................................10
Pad Replacement ......................................................25
DUAL PROPORTIONING VALVE.................................11
Removal.....................................................................26
Inspection...................................................................11
Disassembly...............................................................26
BRAKE PEDAL AND BRACKET..................................12
Inspection...................................................................26
Removal and Installation ...........................................12
CALIPER .................................................................26
Inspection...................................................................12
ROTOR ...................................................................27
Adjustment .................................................................12
Assembly ...................................................................28
MASTER CYLINDER (TOKICO) ...................................14
Installation..................................................................28
Removal.....................................................................14
REAR DISC BRAKE......................................................29
Disassembly...............................................................15
Component ................................................................29
Inspection...................................................................15
Pad Replacement ......................................................29
Assembly ...................................................................15
Removal.....................................................................31
Installation..................................................................16
Disassembly...............................................................32
MASTER CYLINDER (NABCO) ....................................17
Inspection...................................................................33
Removal.....................................................................17
CALIPER .................................................................33
Disassembly...............................................................17 ROTOR ...................................................................33
Inspection...................................................................18 Assembly ...................................................................34
Assembly ...................................................................18 Installation..................................................................36
CONTENTS (Cont'd)
PARKING BRAKE CONTROL ......................................38 Ground Circuit Check ................................................60
Components...............................................................38 ABS ACTUATOR AND ELECTRIC UNIT GROUND.....60
Removal and Installation ...........................................38 TROUBLE DIAGNOSIS - GENERAL
Inspection...................................................................38 DESCRIPTION ...............................................................61
Adjustment .................................................................39 Malfunction Code/Symptom Chart.............................61
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ABS ITEMS.............................................................................62
Wheel Sensor or Rotor..............................................62
DESCRIPTION ...............................................................40 DIAGNOSTIC PROCEDURE .....................................62
Purpose......................................................................40 ABS Actuator Solenoid Valve or Solenoid Valve
ABS (Anti-Lock Brake System) Operation ................40 Relay..........................................................................65
ABS Hydraulic Circuit ................................................40 DIAGNOSTIC PROCEDURE .....................................65
System Components .................................................41 Motor Relay or Motor.................................................68
System Description....................................................41 DIAGNOSTIC PROCEDURE .....................................68
SENSOR .................................................................41 Low Voltage ...............................................................70
CONTROL UNIT ......................................................41 DIAGNOSTIC PROCEDURE .....................................70
ABS ACTUATOR AND ELECTRIC UNIT ....................41 Control Unit................................................................72
Component Parts and Harness Connector DIAGNOSTIC PROCEDURE .....................................72
Location .....................................................................43 TROUBLE DIAGNOSES FOR SYMPTOMS .................73
Schematic ..................................................................44 1. ABS Works Frequently ..........................................73
Wiring Diagram - ABS - .............................................45 2. Unexpected Pedal Action ......................................73
ON BOARD DIAGNOSTIC SYSTEM 3. Long Stopping Distance ........................................74
DESCRIPTION ...............................................................48 4. ABS Does Not Work..............................................75
Self-diagnosis ............................................................48 5. Pedal Vibration and Noise.....................................76
FUNCTION ..............................................................48 6. ABS Warning Lamp Does Not Come On
SELF-DIAGNOSIS PROCEDURE ..............................48 When Ignition Switch Is Turned On...........................77
HOW TO READ SELF-DIAGNOSTIC RESULTS 7. ABS Warning Lamp Stays On When Ignition
(MALFUNCTION CODES) ........................................48
Switch Is Turned On ..................................................79
HOW TO ERASE SELF-DIAGNOSTIC RESULTS
REMOVAL AND INSTALLATION .................................81
(MALFUNCTION CODES) ........................................49
Wheel Sensors ..........................................................81
CONSULT-II ...............................................................50
CONSULT-II APPLICATION TO ABS..........................50
Sensor Rotor..............................................................81
ECU (ABS CONTROL UNIT) PART NUMBER REMOVAL ...............................................................81
MODE .....................................................................50 INSTALLATION........................................................82
CONSULT-II Inspection Procedure............................50 Actuator......................................................................82
SELF-DIAGNOSIS PROCEDURE ..............................50 REMOVAL ...............................................................82
SELF-DIAGNOSTIC RESULTS MODE.......................52 INSTALLATION........................................................82
DATA MONITOR PROCEDURE ................................53
ACTIVE TEST PROCEDURE ....................................54
DATA MONITOR MODE ...........................................55 SERVICE DATA AND SPECIFICATIONS (SDS) .........83
ACTIVE TEST MODE ...............................................55 General Specifications...............................................83
TROUBLE DIAGNOSIS - INTRODUCTION..................56 Disc Brake .................................................................83
How to Perform Trouble Diagnoses for Quick Brake Pedal ...............................................................83
and Accurate Repair ..................................................56 Parking Brake ............................................................83
INTRODUCTION ......................................................56 Control Valve .............................................................84
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........57 Brake Booster ............................................................84
Preliminary Check......................................................57 ABS Wheel Sensor....................................................84
BR-2
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" NFBR0112
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. The SRS system composition which is available to NISSAN MODEL A33 is as follows (The compo-
sition varies according to the destination and optional equipment.):
+ For a frontal collision
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt
pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
+ For a side collision
The Supplemental Restraint System consists of front side air bag module (located in the outer side of front
seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring
harness, warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS 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 should be per-
formed by an authorized NISSAN 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 RS section.
+ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation tape either just
before the harness connectors or for the complete harness are related to the SRS.
Precautions for Brake System NFBR0113
+ Recommended fluid is brake fluid "DOT 3".
+ Never reuse drained brake fluid.
+ Be careful not to splash brake fluid on painted areas.
+ To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
+ Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of the hydraulic system.
+ Use flare nut wrench when removing and installing brake
tube.
SBR686C
+ Always torque brake lines when installing.
+ Burnish the brake 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 "Brake Burnishing Procedure", "ON-VEHICLE
SERVICE", BR-7.
WARNING:
+ Clean brake pads and shoes with a waste cloth, then wipe
with a dust collector.
BR-3
PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
Wiring Diagrams and Trouble Diagnosis NFBR0114
When you read wiring diagrams, refer to the following:
+ GI-11, "HOW TO READ WIRING DIAGRAMS"
+ EL-9, "POWER SUPPLY ROUTING" for power distribution circuit
When you perform trouble diagnosis, refer to the following:
+ GI-33, "HOW TO FOLLOW TEST GROUP IN TROUBLE DIAGNOSIS"
+ GI-22, "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT"
BR-4
PREPARATION
Commercial Service Tools
Commercial Service Tools NFBR0115
Tool name Description
1 Flare nut crowfoot Removing and installing each brake piping
2 Torque wrench a: 10 mm (0.39 in)
NT360
Brake fluid pressure Measuring brake fluid pressure
gauge
NT151
BR-5
16S01
NFBR01
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH
NVH Troubleshooting Chart NFBR01
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
BR-25, BR-29
BR-25, BR-29
BR-25, BR-29
BR-27, BR-33
BR-27, BR-33
AX-3
AX-3
SU-4
SU-4
SU-4
ST-5
--
--
--
--
--
Reference page
Rotor thickness variation
Pads - uneven wear
Rotor deformation
Pads - damaged
Rotor imbalance
Shims damaged
Rotor deflection
ROAD WHEEL
DRIVE SHAFT
SUSPENSION
Possible cause and
Rotor damage
Rotor runout
SUSPECTED PARTS
STEERING
Rotor rust
TIRES
AXLE
Noise X X X X X X X X X
Symptom BRAKE Shake X X X X X X X
Shimmy, Judder X X X X X X X X X X X X
X: Applicable
BR-6
ON-VEHICLE SERVICE
Checking Brake Fluid Level
Checking Brake Fluid Level NFBR0117
+ Check fluid level in reservoir tank. It should be between Max
and Min lines on reservoir tank.
+ If fluid level is extremely low, check brake system for leaks.
+ Release parking brake lever and see if brake warning lamp
goes off. If not, check brake system for leaks.
SBR451D
Checking Brake Line NFBR0118
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SBR389C
Changing Brake Fluid NFBR0119
CAUTION:
+ Refill with new brake fluid "DOT 3".
+ Always keep fluid level higher than minimum line on res-
ervoir tank.
+ 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.
1. Clean inside of reservoir tank, and refill with new brake fluid.
SBR419C
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to "Bleeding Brake System", BR-8.
Brake Burnishing Procedure NFBR0120
Burnish the brake contact surfaces according to the following pro-
cedure after refinishing or replacing drums or rotors, after replac-
ing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic con-
ditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot effort to bring the vehicle to a
complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
BR-7
ON-VEHICLE SERVICE
Brake Burnishing Procedure (Cont'd)
pressure such that vehicle stopping time equals 3 to 5 sec-
onds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3, 10 times or more to complete the burnish-
ing procedure.
Bleeding Brake System NFBR0121
CAUTION:
+ Carefully monitor brake fluid level at master cylinder dur-
ing bleeding operation.
+ Fill reservoir with new brake fluid "DOT 3". Make sure it is
full at all times while bleeding air out of system.
+ Place a container under master cylinder to avoid spillage
of brake fluid.
+ For models with ABS, turn ignition switch OFF and dis-
connect ABS actuator connectors or battery ground cable.
SBR995
+ Bleed air in the following order.
Right rear brake Left front brake Left rear brake Right
front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out of
SBR419C air bleeder valve.
BR-8
BRAKE HYDRAULIC LINE
Hydraulic Circuit
Hydraulic Circuit NFBR0122
SBR666E
Removal NFBR0123
CAUTION:
+ 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.
+ All hoses must be free from excessive bending, twisting
and pulling.
1. Connect vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
SBR992 3. Remove flare nut connecting brake tube and hose, then with-
draw lock spring.
4. Cover openings to prevent entrance of dirt whenever discon-
necting brake line.
Inspection NFBR0124
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
BR-9
BRAKE HYDRAULIC LINE
Installation
Installation NFBR0125
CAUTION:
+ Refill with new brake fluid "DOT 3".
+ Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Specification:
Flare nut
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