Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2001 br
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BRAKE SYSTEM GI
SECTION BR MA
EM
LC
EC
CONTENTS FE
PRECAUTIONS ...............................................................5 On-vehicle Service.....................................................22
CL
Supplemental Restraint System (SRS) AIR OPERATING CHECK ...............................................22
BAG and SEAT BELT PRE-TENSIONER...............5 AIRTIGHT CHECK ...................................................22 MT
Precautions for Brake System.....................................5 Removal.....................................................................22
Wiring Diagrams and Trouble Diagnosis.....................6 Inspection...................................................................22
PREPARATION ...............................................................7 OUTPUT ROD LENGTH CHECK ..............................22 AT
Special Service Tools ..................................................7 Installation..................................................................23
Commercial Service Tools ...........................................7 VACUUM PIPING...........................................................24
NOISE, VIBRATION AND HARSHNESS (NVH) Vacuum Hose ............................................................24 TF
TROUBLESHOOTING .....................................................8 Removal and Installation ...........................................24
NVH Troubleshooting Chart.........................................8 Inspection...................................................................25
HOSES AND CONNECTORS ...................................25
PD
ON-VEHICLE SERVICE ..................................................9
CHECK VALVE ........................................................25
Checking Brake Fluid Level.........................................9
FRONT DISC BRAKE ...................................................26
Checking Brake Line ...................................................9 AX
Pad Replacement ......................................................26
Changing Brake Fluid ..................................................9
Removal.....................................................................27
Brake Burnishing Procedure......................................10
Bleeding Brake System .............................................11
Disassembly...............................................................28 SU
Inspection...................................................................28
BRAKE HYDRAULIC LINE ...........................................12
CALIPER .................................................................28
Hydraulic Circuit.........................................................12
ROTOR ...................................................................28
Removal.....................................................................13
Assembly ...................................................................29
Inspection...................................................................13
Installation..................................................................29
Installation..................................................................13
REAR DRUM BRAKE ...................................................30 ST
PROPORTIONING VALVE (VG33E AND VG33ER) ....14
Components...............................................................30
Inspection...................................................................14
Removal.....................................................................31
Removal and Installation (Built-in type).....................14 RS
Inspection...................................................................32
LOAD SENSING VALVE (KA24DE) .............................15
WHEEL CYLINDER ..................................................32
Inspection...................................................................15
Removal and Installation ...........................................16
Wheel Cylinder Overhaul...........................................32 BT
Inspection...................................................................32
BRAKE PEDAL AND BRACKET..................................17 DRUM .....................................................................32
Removal and Installation ...........................................17 LINING ....................................................................32 HA
Inspection...................................................................17 Installation..................................................................33
Adjustment .................................................................18 LT30A MODEL .........................................................33
MASTER CYLINDER.....................................................19 PARKING BRAKE CONTROL ......................................35 SC
Removal.....................................................................19 Components...............................................................35
Disassembly...............................................................19 Removal and Installation ...........................................36
Inspection...................................................................20 Inspection...................................................................36
EL
Assembly ...................................................................20 Adjustment .................................................................36
Installation..................................................................21 IDX
BRAKE BOOSTER........................................................22
CONTENTS (Cont'd)
KA24DE REAR SENSOR UNIT AND ACTUATOR ....................65
DESCRIPTION ...............................................................37
VG33E AND VG33ER (2WD)
Purpose......................................................................37
Operation ...................................................................37 DESCRIPTION ...............................................................68
ABS Hydraulic Circuit ................................................37 Purpose......................................................................68
System Components .................................................38 Operation ...................................................................68
System Description....................................................38 ABS Hydraulic Circuit ................................................68
REAR SENSOR .......................................................38 System Components .................................................69
ABS CONTROL UNIT...............................................38 System Description....................................................70
Removal and Installation ...........................................39 WHEEL SENSOR ....................................................70
REAR SENSOR .......................................................39 ABS ACTUATOR AND ELECTRIC UNIT
ACTUATOR .............................................................39 (CONTROL UNIT) ....................................................70
TROUBLE DIAGNOSES................................................40 Removal and Installation ...........................................71
How to Perform Trouble Diagnoses for Quick FRONT WHEEL SENSORS ......................................71
and Accurate Repair ..................................................40 REAR WHEEL SENSOR ..........................................71
INTRODUCTION ......................................................40 ABS ACTUATOR AND ELECTRIC UNIT ....................72
WORK FLOW ..........................................................41 TROUBLE DIAGNOSES................................................73
Preliminary Check......................................................42 How to Perform Trouble Diagnoses for Quick
Component Parts and Harness Connector and Accurate Repair ..................................................73
Location .....................................................................45 INTRODUCTION ......................................................73
Schematic ..................................................................46 WORK FLOW ..........................................................74
Wiring Diagram - ABS - .............................................47 Preliminary Check......................................................75
Self-diagnosis ............................................................49 Component Parts and Harness Connector
CHECKING THE NUMBER OF WARNING LAMP Location .....................................................................78
FLASHES ................................................................49 Schematic ..................................................................79
SELF-DIAGNOSIS PROCEDURE 1 ...........................49 Wiring Diagram - ABS - .............................................80
SELF-DIAGNOSIS PROCEDURE 2 ...........................51 ON BOARD DIAGNOSTIC SYSTEM
MALFUNCTION CODE/SYMPTOM CHART ...............52 DESCRIPTION ...............................................................83
Main Power Supply and Ground Circuit Check ........52 Self-diagnosis ............................................................83
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC FUNCTION ..............................................................83
ITEMS.............................................................................56 SELF-DIAGNOSIS PROCEDURE ..............................83
ABS Actuator ISO Solenoid Short or Open...............56 HOW TO READ SELF-DIAGNOSTIC RESULTS
MALFUNCTION CODE NO. 2 OR 7 ..........................56 (MALFUNCTION CODES) ........................................84
ABS Actuator ISO Blocked ........................................57 HOW TO ERASE SELF-DIAGNOSTIC RESULTS
MALFUNCTION CODE NO. 4 ...................................57 (MALFUNCTION CODES) ........................................84
ABS Actuator Dump Solenoid Short Circuit or CONSULT-II ...............................................................85
Open ..........................................................................58 CONSULT-II APPLICATION TO ABS..........................85
MALFUNCTION CODE NO. 3 OR 8 ..........................58 ECU (ABS CONTROL UNIT) PART NUMBER
Rear Sensor Open or Short ......................................60 MODE .....................................................................85
MALFUNCTION CODE NO. 9 OR 10.........................60 CONSULT-II Inspection Procedure............................86
Sensor Signal Erratic.................................................60 SELF-DIAGNOSIS PROCEDURE ..............................86
MALFUNCTION CODE NO. 6 ...................................60 SELF-DIAGNOSTIC RESULTS MODE.......................87
ABS Control Unit .......................................................61 DATA MONITOR PROCEDURE ................................88
MALFUNCTION CODE NO. 13, 14 OR 15 .................61 ACTIVE TEST PROCEDURE ....................................88
ABS Actuator .............................................................61 DATA MONITOR MODE ...........................................90
ACTIVE TEST MODE ...............................................91
MALFUNCTION CODE NO. 5 ...................................61
TROUBLE DIAGNOSES FOR SYMPTOMS .................62 Ground Circuit Check ................................................91
ABS ACTUATOR AND ELECTRIC UNIT GROUND.....91
1. Pedal Vibration or Noise .......................................62
TROUBLE DIAGNOSIS - GENERAL
2. Long Stopping Distance ........................................63
DESCRIPTION ...............................................................92
3. Unexpected Pedal Action ......................................63
Malfunction Code/Symptom Chart.............................92
4. ABS Does Not Work..............................................64
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
5. ABS Works Frequently ..........................................64
ITEMS.............................................................................93
Electrical Components Inspection .............................65
Wheel Sensor or Rotor..............................................93
BR-2
CONTENTS (Cont'd)
MALFUNCTION CODE NO. 21, 22, 25, 26, 35, 36 HOW TO READ SELF-DIAGNOSTIC RESULTS GI
OR 18 .....................................................................93 (MALFUNCTION CODES) ......................................124
ABS Actuator Solenoid Valve and Solenoid Valve HOW TO ERASE SELF-DIAGNOSTIC RESULTS
Relay..........................................................................95 (MALFUNCTION CODES) ......................................124 MA
MALFUNCTION CODE NO. 41, 42, 45, 46, 55, 56 TROUBLE DIAGNOSIS - GENERAL
OR 63 .....................................................................95 DESCRIPTION .............................................................125
Motor Relay or Motor.................................................97 Malfunction Code Chart (Without CONSULT-II)......125 EM
MALFUNCTION CODE NO. 61 .................................97 Symptom Chart........................................................125
Low Voltage ...............................................................99 CONSULT-II .............................................................126
MALFUNCTION CODE NO. 57 .................................99 CONSULT-II APPLICATION TO ABS........................126
LC
Control Unit..............................................................101 ECU (ABS CONTROL UNIT) PART NUMBER
MALFUNCTION CODE NO. 71 ...............................101 MODE ...................................................................126
TROUBLE DIAGNOSES FOR SYMPTOMS ...............102 CONSULT-II Inspection Procedure..........................127
EC
1. ABS Works Frequently ........................................102 SELF-DIAGNOSIS PROCEDURE ............................127
2. Unexpected Pedal Action ....................................103 SELF-DIAGNOSTIC RESULTS MODE.....................128 FE
3. Long Stopping Distance ......................................104 DATA MONITOR PROCEDURE ..............................129
4. ABS Does Not Work............................................104 ACTIVE TEST PROCEDURE ..................................130
DATA MONITOR MODE .........................................131 CL
5. Pedal Vibration and Noise...................................105
ACTIVE TEST MODE .............................................131
6. Warning Lamp Does Not Come On When
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC
Ignition Switch Is Turned ON...................................105
7. Warning Lamp Stays On When Ignition Switch
ITEMS...........................................................................132 MT
Wheel Sensor or Rotor............................................132
Is Turned On............................................................107
DIAGNOSTIC PROCEDURE ...................................132
ABS Actuator Solenoid Valve or Solenoid Valve AT
VG33E AND VG33ER (4WD) Relay........................................................................135
DESCRIPTION .............................................................110 DIAGNOSTIC PROCEDURE ...................................135
Motor Relay or Motor...............................................137 TF
Purpose....................................................................110
Operation .................................................................110 DIAGNOSTIC PROCEDURE ...................................137
Low Voltage .............................................................139
ABS Hydraulic Circuit ..............................................110
DIAGNOSTIC PROCEDURE ...................................139
PD
System Components ............................................... 111
G Sensor and Circuit ...............................................141
System Description.................................................. 111
DIAGNOSTIC PROCEDURE ...................................141 AX
WHEEL SENSOR .................................................. 111
Control Unit..............................................................143
CONTROL UNIT (BUILT-IN ABS ACTUATOR AND
DIAGNOSTIC PROCEDURE ...................................143
ELECTRIC UNIT) ................................................... 111
ABS ACTUATOR AND ELECTRIC UNIT ..................112 TROUBLE DIAGNOSES FOR SYMPTOMS ...............144 SU
G SENSOR ...........................................................112 1. ABS Works Frequently ........................................144
TROUBLE DIAGNOSIS - INTRODUCTION................113 2. Unexpected Pedal Action ....................................144
How to Perform Trouble Diagnoses for Quick 3. Long Stopping Distance ......................................146
and Accurate Repair ................................................113 4. ABS Does Not Work............................................146
INTRODUCTION ....................................................113 5. Pedal Vibration and Noise...................................146
6. Warning Lamp Does Not Come On When
ST
TROUBLE DIAGNOSIS - BASIC INSPECTION .........114
Preliminary Check....................................................114 Ignition Switch Is Turned On ...................................147
Ground Circuit Check ..............................................117 7. Warning Lamp Stays On When Ignition Switch RS
ABS ACTUATOR AND ELECTRIC UNIT GROUND...117 Is Turned On............................................................148
Component Parts and Harness Connector REMOVAL AND INSTALLATION ...............................152
Location ...................................................................118 Front Wheel Sensor.................................................152 BT
Schematic ................................................................119 Rear Wheel Sensor .................................................152
Wiring Diagram - ABS - ...........................................120 Front Sensor Rotor ..................................................153
ON BOARD DIAGNOSTIC SYSTEM REMOVAL .............................................................153 HA
DESCRIPTION .............................................................123 INSTALLATION......................................................153
Self-diagnosis (Without CONSULT-II) .....................123 Rear Sensor Rotor...................................................153
REMOVAL .............................................................153
SC
FUNCTION ............................................................123
SELF-DIAGNOSIS PROCEDURE ............................123 INSTALLATION......................................................153
G Sensor..................................................................153 EL
IDX
BR-3
CONTENTS (Cont'd)
ABS Actuator and Electric Unit................................154 Disc Brake ...............................................................155
REMOVAL .............................................................154 Drum Brake..............................................................155
INSTALLATION......................................................154 Brake Pedal .............................................................155
Parking Brake Control .............................................156
SERVICE DATA AND SPECIFICATIONS (SDS) .......155
General Specifications.............................................155
BR-4
PRECAUTIONS
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER"
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER" used along with
NEBR0199
GI
a seat belt, help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The Supplemental Restraint System consists of air bag modules (located in the center of the steering wheel MA
and in the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warn-
ing lamp, wiring harness, and spiral cable.
The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch. Because no EM
rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the pas-
senger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is
located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, LC
the passenger air bag is enabled and could inflate in a frontal collision. When the switch is turned to the OFF
position, the passenger air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF
indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag EC
always remains enabled and is not affected by the passenger air bag deactivation switch.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING: FE
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