Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti I35 A33 2002-2004 Approved Infiniti I35 2003 br
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BRAKE SYSTEM
GI
SECTION BR MA
EM
LC
EC
CONTENTS
FE
PRECAUTIONS ...............................................................4 OPERATING CHECK ...............................................19
Supplemental Restraint System (SRS) AIR AIRTIGHT CHECK ...................................................19 AT
BAG and SEAT BELT PRE-TENSIONER...............4 Removal.....................................................................19
Precautions for Brake System.....................................4 Inspection...................................................................19
Wiring Diagrams and Trouble Diagnosis.....................4 OUTPUT ROD LENGTH CHECK ..............................19 AX
PREPARATION ...............................................................5 Installation..................................................................19
Commercial Service Tools ...........................................5 VACUUM HOSE.............................................................21
Removal and Installation ...........................................21 SU
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................6 Inspection...................................................................21
NVH Troubleshooting Chart.........................................6 HOSES AND CONNECTORS ...................................21
CHECK VALVE ........................................................21
ON-VEHICLE SERVICE ..................................................7
FRONT DISC BRAKE ...................................................22
Checking Brake Fluid Level.........................................7
Component ................................................................22 ST
Checking Brake Line ...................................................7
Pad Replacement ......................................................22
Changing Brake Fluid ..................................................7
Removal.....................................................................23
Brake Burnishing Procedure........................................7
Bleeding Brake System ...............................................8
Disassembly...............................................................23 RS
Inspection...................................................................24
BRAKE HYDRAULIC LINE .............................................9
CALIPER .................................................................24
Hydraulic Circuit...........................................................9 BT
ROTOR ...................................................................24
Removal.......................................................................9
Assembly ...................................................................25
Inspection.....................................................................9
Installation..................................................................25
Installation..................................................................10
REAR DISC BRAKE......................................................26
HA
BRAKE PEDAL AND BRACKET..................................11
Component ................................................................26
Removal and Installation ...........................................11
Pad Replacement ......................................................26 SC
Inspection...................................................................11
Removal.....................................................................28
Adjustment .................................................................11
Disassembly...............................................................29
MASTER CYLINDER (TOKICO) ...................................13 EL
Inspection...................................................................30
Removal.....................................................................13
CALIPER .................................................................30
Disassembly...............................................................14 ROTOR ...................................................................30
Inspection...................................................................14 Assembly ...................................................................31 IDX
Assembly ...................................................................14 Installation..................................................................33
Installation..................................................................15 PARKING BRAKE CONTROL ......................................34
MASTER CYLINDER [BOSCH (NABCO)] ...................16 Components...............................................................34
Removal.....................................................................16 Removal and Installation ...........................................34
Disassembly...............................................................17 Inspection...................................................................34
Inspection...................................................................17 Adjustment .................................................................35
Assembly ...................................................................17
Installation..................................................................18
TCS
BRAKE BOOSTER........................................................19
On-vehicle Service.....................................................19 DESCRIPTION ...............................................................36
CONTENTS (Cont'd)
Purpose......................................................................36 CAN Communication System ....................................73
ABS (Anti-Lock Brake System) Operation ................36 INSPECTION PROCEDURE .....................................73
ABS Hydraulic Circuit ................................................36 Engine System...........................................................73
TCS (Traction Control System) Operation ................37 DIAGNOSTIC PROCEDURE .....................................73
System Components .................................................37 A/T System ................................................................74
System Description....................................................38 DIAGNOSTIC PROCEDURE .....................................74
SENSOR .................................................................38 TROUBLE DIAGNOSES FOR SYMPTOMS .................75
CONTROL UNIT ......................................................38 1. ABS Works Frequently ..........................................75
ACTUATOR .............................................................38 2. Unexpected Pedal Action ......................................75
Component Parts and Harness Connector 3. Long Stopping Distance ........................................76
Location .....................................................................40 4. ABS Does Not Work..............................................77
Schematic ..................................................................41 5. Pedal Vibration and Noise.....................................78
Wiring Diagram - TCS -.............................................42 6. ABS Warning Lamp Does Not Come On
ON BOARD DIAGNOSTIC SYSTEM When Ignition Switch Is Turned On...........................79
DESCRIPTION ...............................................................46 7. ABS Warning Lamp Stays On When Ignition
CONSULT-II Functions ..............................................46 Switch Is Turned On ..................................................80
CONSULT-II MAIN FUNCTION ..................................46 8. SLIP Indicator Lamp Does Not Come On
ECU (ABS/TCS CONTROL UNIT) PART NUMBER When Ignition Switch Is Turned On...........................83
MODE .....................................................................46 9. TCS OFF Indicator Lamp Does Not Come On
CONSULT-II Inspection Procedure............................46 When Ignition Switch Is Turned On...........................84
SELF-DIAGNOSIS PROCEDURE ..............................46 10. TCS OFF Switch Is Inoperative ..........................86
SELF-DIAGNOSTIC RESULTS MODE.......................48
11. Poor Acceleration.................................................89
DATA MONITOR PROCEDURE ................................49
ABS ACTUATOR AND ELECTRIC UNIT
ACTIVE TEST PROCEDURE ....................................49
(CONTROL UNIT)..........................................................90
DATA MONITOR MODE ...........................................50
ACTIVE TEST MODE ...............................................52 Removal.....................................................................90
TROUBLE DIAGNOSIS - INTRODUCTION..................53 Installation..................................................................90
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................53 VDC
INTRODUCTION ......................................................53
PRECAUTIONS .............................................................91
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........54
Supplemental Restraint System (SRS) AIR
Preliminary Check......................................................54
BAG and SEAT BELT PRE-TENSIONER.............91
Ground Circuit Check ................................................57
Precautions for Brake System...................................91
ABS ACTUATOR AND ELECTRIC UNIT
Precautions for Brake Control ...................................92
(CONTROL UNIT) GROUND.....................................57
Precautions for CAN System.....................................92
TROUBLE DIAGNOSIS - GENERAL
FOR INSPECTION ...................................................92
DESCRIPTION ...............................................................58
FOR HARNESS REPAIR ..........................................92
Malfunction Code/Symptom Chart.............................58
ON-VEHICLE SERVICE ................................................94
CAN COMMUNICATION ...............................................60
Adjustment of Neutral Position of Steering Angle
System Description....................................................60
Sensor........................................................................94
FOR TCS MODELS .................................................60
GENERAL INFORMATION ...........................................96
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
Fail-safe .....................................................................96
ITEMS.............................................................................61
ABS SYSTEM ..........................................................96
Wheel Sensor or Rotor..............................................61
VDC/TCS SYSTEM ..................................................96
DIAGNOSTIC PROCEDURE .....................................61
Hydraulic Circuit.........................................................97
ABS Actuator Solenoid Valve or Solenoid Valve
ABS Functions ...........................................................97
Relay..........................................................................65
TCS Functions ...........................................................98
DIAGNOSTIC PROCEDURE .....................................65
VDC Functions...........................................................98
Motor Relay or Motor.................................................68
System Diagram ........................................................99
DIAGNOSTIC PROCEDURE .....................................68
CAN COMMUNICATION .............................................100
Low Voltage ...............................................................70
DIAGNOSTIC PROCEDURE .....................................70
System Description..................................................100
FOR VDC MODELS ...............................................100
Control Unit................................................................72
DIAGNOSTIC PROCEDURE .....................................72
TROUBLE DIAGNOSIS - INTRODUCTION................101
BR-2
CONTENTS (Cont'd)
How to Perform Trouble Diagnoses for Quick Inspection 13 When ST ANG SEN SIGNAL is
and Accurate Repair ................................................101 Indicated in The Self-diagnosis Results ..................155
INTRODUCTION ....................................................101 Inspection 14 Brake Fluid Level of Reservoir GI
WORK FLOW ........................................................102 Tank .........................................................................156
ASKING COMPLAINTS ..........................................103 Inspection 15 CAN Communication System,
EXAMPLE OF DIAGNOSIS SHEET .........................103
MA
VDC/TCS/ABS Control Unit and Steering Angle
Component Parts and Harness Connector Sensor......................................................................157
Location ...................................................................104 Component Check ...................................................158 EM
Schmatic ..................................................................105 VDC OFF SWITCH ................................................158
Wiring Diagram -VDC/TCS/ABS- ............................106 VDC RELAY BOX ..................................................158
Control Unit Input/Output Signal Standard..............114 ABS ACTUATOR ...................................................159 LC
STANDARDS USING A CIRCUIT TESTER AND TROUBLE DIAGNOSES FOR SYMPTOMS ...............161
OSCILLOSCOPE ...................................................114 Symptom 1: ABS Works Frequently........................161
STANDARDS WITH CONSULT-II ............................117 Symptom 2: Unexpected Pedal Action....................161 EC
CONSULT-II Functions ............................................119 Symptom 3: Longer Stopping Distance...................162
CONSULT-II MAIN FUNCTION ................................119
Symptom 4: ABS Does Not Work ...........................163
SELF-DIAGNOSIS .................................................120 FE
Symptom 5: Pedal Vibration and Noise ..................163
DATA MONITOR....................................................124
Symptom 6: VDC OFF Indicator Lamp Does Not
ACTIVE TEST ........................................................126
For Correct and Quick Diagnosis ............................130 Illuminate..................................................................164 AT
PRECAUTIONS FOR TROUBLE DIAGNOSIS ..........130 Symptom 7: SLIP Indicator Lamp Does Not
TROUBLE DIAGNOSIS - BASIC INSPECTION .........132 Illuminate..................................................................165
Preliminary Check 1: (Brake Fluid Level and Symptom 8: During VDC/TCS/ABS Control, AX
Leak Inspection) ......................................................132 Vehicle Behavior is Jerky ........................................165
Preliminary Check 2: (Inspection for Loose VDC/TCS/ABS CONTROL UNIT.................................167
Removal and Installation .........................................167
SU
Power Supply Terminal)...........................................132
Preliminary Check 3: (Inspection for ABS REMOVAL .............................................................167
INSTALLATION......................................................167
Warning Lamp, VDC OFF Indicator Lamp, and
ABS ACTUATOR AND VDC RELAY BOX ................168
SLIP Indicator Lamp)...............................................132
Removal and Installation .........................................168
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
ITEMS...........................................................................134
YAW RATE/SIDE G SENSOR.....................................169 ST
Removal and Installation .........................................169
Inspection 1 Wheel Sensor and Circuit...................134
REMOVAL .............................................................169
Inspection 2 Engine System....................................136 RS
INSTALLATION......................................................169
Inspection 3 VDC/TCS/ABS Control Unit System...137
VDC OFF SWITCH ......................................................170
Inspection 4 Pressure Sensor and The Circuit
Removal and Installation .........................................170
Between Pressure Sensor and VDC/TCS/ABS REMOVAL .............................................................170 BT
Control Unit..............................................................138 INSTALLATION......................................................170
Inspection 5 Steering Angle Sensor and The
Circuit Between Steering Angle Sensor and HA
TCS/VDC
VDC/TCS/ABS .........................................................140
Inspection 6 Yaw Rate/Side G and The Circuit REMOVAL AND INSTALLATION ...............................171
Wheel Sensors ........................................................171
SC
Between Yaw Rate/Side G and VDC/TCS/ABS
Control Unit..............................................................142 Sensor Rotor............................................................171
Inspection 7 Solenoid Valve, VDC Switch-over REMOVAL .............................................................171 EL
Solenoid Valve and Circuit ......................................143 INSTALLATION......................................................172
Inspection 8 Actuator Motor, Motor Relay and
Circuit.......................................................................147 SERVICE DATA AND SPECIFICATIONS (SDS) .......173 IDX
Inspection 9 Actuator Relay and Circuit ..................149 General Specifications.............................................173
Inspection 10 Stop Lamp Switch and Circuit ..........151 Disc Brake ...............................................................173
Inspection 11 VDC/TCS/ABS Control Unit Power Brake Pedal .............................................................173
Supply Circuit...........................................................152 Parking Brake ..........................................................173
Inspection 12 When EMERGENCY BRAKE Is Brake Booster ..........................................................173
Indicated in The Self-diagnosis Results ..................155 ABS Wheel Sensor..................................................173
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 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:
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