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BRAKE SYSTEM SECTION BR CONTENTS

1. 4 T 9 2 R SMG FS EW SELENE e 6 8 3H 9 10 9 u Olt L4 Rear LH Front RH Front LH Rear RH wheel wheel wheel wheel NBR259 D Inlet solenoid valve Pump Bypass check valve 2 Outlet solenoid valve Motor Damper 3 Reservoir BR 50 ANTI LOCK BRAKE SYSTEM System Components Brake tube connector Actuator Control unit Front wheel sensors Warning light Rear wheel sensors NBR260 Sensor proxi mity detector Magnetic flux Control unit Tooth time of one tooth IN Pf V Induced electromotive force SBR124B ABS warning light NBR284 System Description SENSOR The sensor unit consists of a gear shaped sensor rotor and an electro magnetic proximity detector The proximity detector pick up contains a bar magnet around which a coil is wound The detector is installed on the back side of the brake rotor An alternating voltage is generated in the coil of the proximity detec tor as each tooth of the rotor cuts the magnetic field of the detector core The frequency and amplitude of the voltage increases in proportion to the rota
2. 13 INS POCHO aiie 13 Adjustment cie 13 MASTER CYLINDER eene 15 Removal sisie iieii sneiru nenn aieea eeina 15 Disassembly tret ent aen hue ERE ERI EUR 15 Inispection eet eter eret aiti 16 Assembly eR ORE EU a 16 17 BRAKE 18 On vehicle 18 18 7 ON t 19 Installatiott z 19 VACUUM ier te err earns 20 Removal and Installation 21 21 FRONT DISC BRAKE 23 Pad Replacement Disassembly Inspection Caliper 5 200 FRONT DISC BRAKE 26 Pad 26 28 HermoVval 29 Disassembly aeeie eniti tei 29 Inspection 29 222 1 FRONT DISC BRAKE
3. 50 50 Me 50 ABS Hydraulic 22 50 System Components 51 System Description 51 Removal and Installation 53 TROUBLE DIAGNOSES 57 How to Perform Trouble Diagnoses for Quick and Accurate 57 Preliminary Check seen 59 Component Parts and Harness Connector opis 60 Circuit Diagram for Quick Pinpoint Check 61 When you read wiring diagrams Wiring Diagram ABS 62 Self diagnosis Only models with data link connector terminal 8 67 TROUBLE DIAGNOSIS GENERAL 2 1 1 69 CONSULT 69 CONSULT II Inspection Procedure 70 Ground Circuit 75 TROUBLE DIAGNOSIS GENERAL 5 1 76 Malfunction Code Symptom 76 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC exe ettet 77 Diagnostic Procedure 1 Wheel sensor or rotor 77 Diagnostic Procedure 2 ABS actuator solenoid valve and solenoid valv
4. 1 1 1 5 Kg m 8 0 10 8 ft lb GY NBR171 1 Disconnect battery cable 2 Drain brake fluid Refer to 7 3 Unlock the slider then disconnect the electrical harness con nectors from ABS control unit 4 Identify each brake pipe with corresponding actuator port hole and mark them accordingly 5 Disconnect brake pipes and move them away from actuator Do not force brake pipes so as to kink them or bend them excessively Ensure that brake fluid does not come into contact with any parts 6 Loosen remove mounting nuts between actuator and bracket CAUTION After installation pay attention to the following points e Refill brake fluid and bleed air Refer to CHECK AND ADJUSTMENT BR 7 and BLEEDING BRAKE SYSTEM BR 8J respectively e The installation procedure is as follows 1 Install actuator on bracket without tightening fixings 2 Assemble brake tubes to actuator without tightening tube nuts Ensure that correct tubes are connected to each port 3 Fully tighten actuator and bracket fixings to specified torque 4 Fully tighten flare nuts to specified torque BR 10 5 Secure ABS control unit harness connector and battery cable BR 56 TROUBLE DIAGNOSES SEF234G How to Perform Trouble Diagnoses for Quick and Accurate Repair INTRODUCTION The ABS system has an electronic control unit to control major braking functions The control unit a
5. 31 Inspection Rotor 31 hti 31 Installation etri 32 REAR DISC BRAKE 1 33 33 Pad 33 35 Disassetmbly nite tetti senses 35 8 1 12 36 ASSSmDbIy 37 8 39 REAR DISC BRAKE 2 40 40 Pad 42222 40 Removal 42 BIET ect 42 4 42 facile ERE 43 REAR DRUM BRAKE 44 Components 44 M 44 Inspection Wheel 45 Wheel Cylinder 46 Inspection DIUM sess idee ette 46 Inspection Lining cette Pt nee 46 8 46 PARKING BRAKE CONTROL 48 Removal and Installation 48 Inspection escort p ERR ERR EA 49 Adjustment esee 49 ANTI LOCK BRAKE
6. Removal WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials CAUTION Suspend caliper assembly with wire so as not to stretch brake hose Remove torque member fixing bolts and connecting bolt It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly BR 24 FRONT DISC BRAKE Disassembly WARNING Do not place your fingers in front of piston CAUTION Do not scratch or score cylinder wall 1 Push out piston with dust seal with compressed air 2 Remove piston seal with suitable tool SBR772 Inspection Caliper CYLINDER BODY e Check inside surface of cylinder for score rust wear dam age or presence of foreign materials If any of the above conditions are observed replace cylinder body e Minor damage from rust or foreign materials may be elimi nated by polishing surface with a fine emery paper Replace cylinder body if necessary CAUTION Use brake fluid to clean Never use mineral oil PISTON CAUTION Piston sliding surface is plated Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface Check piston for score rust wear damage or presence of for eign materials Replace if any of the above conditions are observed SLIDE PIN PIN BOLT AND PIN BOOT Check for wear cracks or other damage Replace if any of the above conditions are
7. AIR BAG C2SSE01 SELECT DIAG MODE SELF DIAG RESULTS DATA MONITOR ACTIVE TEST ECU PART NUMBER C2SDM01 SELECT TEST ITEM FR RH SOL FR LH SOL RR SOL ABS MOTOR C2STIO1 FR RH SOL SELECT MONITOR ITEM MAIN SIGNALS SELECTION FROM MENU 2 501 CONSULT II Inspection Procedure Cont d ACTIVE TEST PROCEDURE e When conducting Active test vehicle must be stationary e When ABS warning lamp stays on never conduct Active test 1 Turn ignition switch to the LOCK position 2 Connect CONSULT II to Data Link Connector 3 Start engine ________ _____ 1 Touch START on CONSULT II screen 3 2 Touch ABS 3 Touch ACTIVE TEST a 5 1 Select active test item by touching screen 2 Touch START a Carry out the active test by touching screen key BR 74 Trouble Diagnosis General Description ACTIVE TEST MODE TEST ITEM CONDITION FR RH SOLENOID FR LH SOLENOID RR RH SOLENOID RR LH SOLENOID Engine is running ABS MOTOR CONSULT II Inspection Procedure Cont d JUDGEMENT Brake fluid pressure control operation IN SOL OUT SOL UP Increase OFF OFF KEEP Hold ON OFF DOWN Decrease ON ON ABS actuator motor ON Motor runs ABS motor relay ON OFF Motor stops ABS motor relay OFF Note Active test will automatically stop ten seconds after the test starts
8. Stop lamp switch Front right inlet solenoid valve Front right outlet solenoid valve Front left inlet solenoid valve Front left outlet solenoid valve Rear right inlet solenoid valve Rear left inlet solenoid valve Rear right outlet solenoid valve Rear left outlet solenoid valve xxix lt x Actuator solenoid valve relay Actuator motor relay ABS MOTOR is shown on the Data Monitor screen ABS warning lamp Battery voltage X Control unit X Applicable Not applicable ECU part number mode Ignore the ECU part number displayed in the ECU PART NUMBER MODE Refer to parts catalog to order the ECU BR 69 Trouble Diagnosis General Description C CONSULT II Inspection Procedure SELF DIAGNOSIS PROCEDURE 1 Turn ignition switch to the LOCK position Data lin corinector 2 Connect CONSULT II to Data Link Connector NEF125A 1 Start engine 2 Drive vehicle over 30 km h 19 mph for at least one minute E NISSAN CONSULT II 1 Stop vehicle with engine run ning and touch START on CONSULT II screen 2 Touch ABS 8 3 Touch SELF DIAG RESULTS e The screen shows the detected AED99A START SUB MODE C2NCS01 malfunction and how many times the ignition switch has been turned since the malfunction ENGI
9. gis com Adjusting nut Warning lamp connec tor NBR171 6 Remove cable mounting bracket and lock plate disc brake Ed only S For drum brake models refer to Removal REAR DRUM NN BRAKE BR 44 NBR163 BR 48 PARKING BRAKE CONTROL SBR768E 196 N 20 kg 44 Ib 7 SBR033A Inspection 1 Check control lever for wear or other damage Replace if necessary 2 Check wires for discontinuity or deterioration Replace if nec essary 3 Check warning lamp and switch Replace if necessary 4 Check parts at each connecting portion and if found deformed or damaged replace the parts Adjustment Before or after adjustment pay attention to the following points e Make sure the toggle lever of the rear disc brakes returns to stopper when the parking lever is released e There is no drag when parking brake lever is released e Vehicle is unladen 1 Adjust clearance between shoe and drum or pad and rotor as follows a Release parking brake lever and loosen adjusting nut b Depress brake pedal fully at least 10 times with engine run ning 2 Pull control lever 10 times or more to make a lever stroke of 203 5 mm 8 01 in At 6 8 notches adjust the parking brake cable by turning the adjusting nut 3 Pull control lever with the specified amount of force Check lever stroke and ensure smooth operation Number of notches 6 8 4
10. REAR AXLE 2 Remove the sensor rotor using suitable puller drift and bear ing replacer Installation Install the sensor rotor For front sensor rotor use hammer and wooden block For rear sensor rotor use suitable drift and press e Always replace sensor rotor with new one e Ensure sensor rotor is completely flush with surface indicated on drive shaft e Pay attention to the flush position of rear sensor rotor as shown in figure h 0 3 to 0 3 mm 0 012 to 0 012 in CONTROL UNIT Location Built in ABS actuator When disconnecting the harness connector pull the lever as shown figure BR 54 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d ABS ACTUATOR Front master cylinder secondary 295 To front wheel cylinder RH bcm ZB TOME erences To front wheel cylinder LH To rear wheel cylinder LH 27 From master cylinder primary To rear wheel cylinder RH 22 10 14 1 0 1 4 7 2 10 1 ABS actuator amp electric control unit Actuator ground cable 7 9 0 7 0 9 5 1 6 5 1 1 1 5 8 0 10 8 0 0 11 15 1 1 1 5 8 0 10 8 Actuator bracket 9 kg m in Ib Nem kg m ft lb NBR262 BR 55 ANTI LOCK BRAKE SYSTEM Removal and Installation Cont d m ABS control unit har 4 ness connector NBR249 ABS actuator AN 10 8 14 7
11. BRAKE SYSTEM x BH CONTENTS PRECAUTIONS 3 Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER 3 Precautions for Brake 3 Precautions When Working On ABS 4 Wiring Diagrams and Trouble Diagnosis 4 PRECAUTIONS AND PREPARATION 5 Commercial Service 5 5 NOISE VIBRATION AND HARSHNESS NVH TROUBLE 6 NVH Troubleshooting 6 CHECK AND ADJUSTMENT 7 Checking Brake Fluid Level 7 Checking Brake 2 2 2 2 7 Changing Brake 10 7 Brake Burnishing 7 Bleeding Brake 8 BRAKE HYDRAULIC 9 5 eire mre esi 10 10 10 CONTROL VALVE 11 Dual Proportioning Valve 11 BRAKE PEDAL AND 13 Removal and Installation
12. SBR236E MASTER CYLINDER Installation CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid 1 Place master cylinder onto brake booster and secure mount ing nuts lightly 2 Torque mounting nuts 14 17 N m 1 5 1 7 kg m 11 12 ft lb 3 Fill up reservoir tank with new brake fluid 4 Plug all ports on master cylinder with fingers to prevent air suction while releasing brake pedal 5 Have driver depress brake pedal slowly several times until no air comes out of master cylinder 6 Fit brake lines to master cylinder 7 Tighten flare nuts 3 15 18 N m 1 5 1 8 kg m 11 13 ft Ib 8 Connect fluid level connector 9 Bleed from brake system Refer to Bleeding Brake System BR 17 BRAKE BOOSTER On vehicle Service OPERATING CHECK 1 Depress brake pedal several times with engine off After exhausting vacuum make sure there is no change in pedal stroke 2 Depress brake pedal then start engine If pedal goes down slightly operation is normal 5 002 AIRTIGHT CHECK OK NG 1 Start engine and stop it after one or two minutes Depress brake pedal several times slowly Booster is airtight if pedal stroke is less each time 2 Depress brake pedal while engine is running and stop 55456 engine with pedal depressed pedal stroke should not Third NN change after holding pedal down for 30 seconds Second SBR365AA Removal
13. lamp ABS control unit 1 21 CVT models 22 M T models NBR415 Diagnostic Procedure 10 Pedal vibration and noise Cont d Applying brake gradually when shifting or operating clutch Low friction slippery road High speed concerning Driving over bumps and pot holes Engine speed is over 5 000 rpm with vehicle stopped Diagnostic Procedure 11 ABS Warning lamp does not come on when ignition switch is s DISCONNECT CR 24 1 2 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 1 E78 1 21 models 7 22 M T models NBR416 turned ON CHECK FUSE Replace fuse Check 10A fuse 12 For fuse layout refer to POWER SUPPLY ROUTING in EL section No CHECK ABS CONTROL UNIT 9 Go to next page POWER SUPPLY CIRCUIT 1 Install 10A fuse 2 Disconnect ABS actuator and elec tric unit connector 3 Check voltage between control unit connector terminal 21 22 and ground after turning ignition switch ON Yes Go to next page BR 88 TROUBLE DIAGNOSES FOR SYMPTOMS ABS warning light NBR284 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR L T 1 21 CVT models 22 M T models NBR417 Diagnostic Procedure 11 ABS Warning lamp does not come on when ignition switch is turned ON Cont d CHECK WARNING LAMP INDICA TION Disc
14. ABS MOTOR RELAY ABNORMAL Circuit for actuator motor is open or shorted e Actuator motor relay is stuck Circuit for actuator is open or shorted BATTERY VOLT VB LOW e Power source voltage supplied to ABS control unit is abnormally low CONTROL UNIT e Function of calculation in ABS control unit has failed If one or more wheels spin on a rough or slippery road for 40 seconds or more the ABS warning lamp will illuminate This does not indicate a malfunction Only in the case of the short circuit after repair the ABS warning lamp also illuminates when the igni tion switch is turned ON In this case drive the vehi as specified in SELF DIAGNOSIS PROCEDURE vehicle is being driven BR 71 speeds greater than 30 km h 19 MPH for approximately 1 minute Check to ensure that the ABS warning lamp goes out while the Trouble Diagnosis General Description NISSAN CONSULTI AED99A START SUB MODE C2NCS01 CONSULT II Inspection Procedure Cont d DATA MONITOR PROCEDURE 1 Turn ignition switch to the off position 2 Connect CONSULT II to Data Link Connector 3 Turn ignition switch to the ON position 1 Touch START CONSULT II screen E 2 Touch ABS 3 Touch DATA MONITOR ENGINE AIR BAG C2SSE01 8 1 Select SELECT MONITOR ITEM v Carry out the monitor test under the condition
15. Fusible link ABS actuator and electric solenoid valve relay Diagnostic Procedure 3 Motor Relay or motor Malfunction code No 61 for models with self diagnosis function CHECK FUSIBLE LINK Check 40A fusible link i Petrol engine fusible link f diesel engine For fusible link layout refer to POWER SUPPLY ROUTING in EL section ABS control unit ABS actuator and electric unit connector GS With petrol engine With diesel engine NG Go to next page CHECK CONNECTOR 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose connection Then reconnect connector 2 Carry out self diagnosis again Does warning lamp activate again YBR177 SS DISCONNECT TS ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 30 E78 YBR178 Yes CHECK MOTOR RELAY POWER SUP PLY CIRCUIT 1 Disconnect ABS actuator and electric unit connector 2 Check voltage between ABS actuator and electric unit connector body side terminal and ground Battery voltage should exist Inspection end Check the following e Harness connector E78 e Harness for open or short between ABS actuator and electric unit and fusible link If NG repair harness or connector CHECK ABS ACTUATOR AND ELEC TRIC UNIT GROUND Refer to ABS ACTUATOR AND ELEC TR
16. Installation CAUTION e Refill with new brake fluid DOT 4 Concave portion e Never reuse drained brake fluid 1 Install caliper assembly e As shown in the figure align the piston s concave to the pad s convex then install the cylinder body to the torque member 2 Install brake hose to caliper securely 3 Install all parts and secure all bolts EROS 4 Bleed air Refer to Bleeding Brake System BR 8 BR 39 REAR DISC BRAKE TYPE 2 Component 7 13 17 20 1 7 2 0 12 14 0 8 1 3 62 115 8 22 31 2 3 3 2 17 23 3 52 3 9 5 3 28 38 OJ N m kg m ft 1b P PBC Poly Buty Cuprysil grease or silicone based grease point NBR440 1 Cylinder body 5 Inner shim 8 Outer shim 2 Pin 6 Inner pad 9 Bleed valve 3 Pin boot 7 pad 10 Connecting bolt 4 Torque member NOTE The cylinder body cannot be disassembled Pad Replacement WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials CAUTION e When cylinder body is open do not depress brake pedal because piston will pop out e Becareful not to damage piston boot or get oil on rotor Always replace shims in replacing pads e f shims are rusted or show peeling of rubber coat replace them with new shims e Itis not necessary to remove connecting bolt except for replacement of caliper assembly
17. LIMIT SIGNAL monitor shows ON gt DISCONNECT TS ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 28 31 E78 YBR170 Ground Circuit Check ABS ACTUATOR AND ELECTRIC UNIT GROUND e Check resistance between ABS actuator and electric unit connector terminals and ground Resistance approximately 00 BR 75 Trouble Diagnosis General Description Malfunction Code Symptom Chart MODELS WITH SELF DIAGNOSIS FUNCTION Code No No of LED flashes Malfunctioning part Reference page 12 Self diagnosis could not detect any malfunctions 18 Sensor rotor 77 21 Front right sensor open circuit BR 77 22 Front right sensor short circuit 77 25 Front left sensor open circuit BR 77 26 Front left sensor short circuit 77 31 Rear right sensor open circuit 77 32 Rear right sensor short circuit BR 77 35 Rear left sensor open circuit 77 36 Rear left sensor short circuit 77 41 Actuator front right outlet solenoid valve BR 79 42 Actuator front right inlet solenoid valve BR 79 45 Actuator front left outlet solenoid valve BR 7d 46 Actuator front left inlet solenoid valve BR 7d 51 Actuator rear right outlet solenoid valve BR 79 52 Actuator rear right inlet solenoid valve BR 79 55 Actuator rear left outlet solenoid valve BR 79 56 Actuator rear left inlet solenoid valve BR 79 57 Power supply Low voltage BR 83 61 Actuator motor or moto
18. Pads uneven wear Shims damaged Rotor imbalance Rotor damaged Rotor runout Rotor deformation Rotor deflection Rotor rust ROAD WHEEL NHV in FA section AXLE SHAFT NHV in FA section STEERING NHV in ST section sued eoejdai Jo j wojdwAs esneo y djay yeyo y esf neyo HAN SNILOOHS HAN SS3NHSHVH 3SION CHECK AND ADJUSTMENT NBR141 ABR159 SBR419C Checking Brake Fluid Level e Check fluid level in reservoir tank It should be between Max and Min lines on reservoir tank e f fluid level is extremely low check brake system for leaks e f brake warning lamp comes on and fluid level is above MIN mark check brake fluid level switch and parking brake switch Checking Brake Line 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 Changing Brake Fluid CAUTION e Refill with new brake fluid DOT 4 e Always keep fluid level higher than minimum line on reservoir tank e Never reuse drained brake flu
19. Replace cylinder body if necessary Torque Member Check for wear cracks or other damage Replace if necessary Piston CAUTION Piston sliding surface is plated Do not polish with emery paper even if rust or foreign matter is stuck to sliding sur face Check piston for score rust wear damage or presence of for eign materials Replace if any of the above conditions are observed BR 36 REAR DISC BRAKE TYPE 1 SBR219C O ring e J a Strut Push rod R Rubber grease BBHodgH Inspection Cont d Pin and Pin Boot Check for wear cracks or other damage Replace if any of the above conditions are observed Rotor Rubbing Surface Check rotor for roughness cracks or chips Runout 1 Secure rotor to wheel hub with two nuts M12 x 1 25 2 Check runout using a dial indicator Make sure that axial end play is within the specifications before measuring Refer to RA section REAR WHEEL BEARING On vehicle Service 3 Change relative positions of rotor and wheel hub so that runout is minimized Maximum runout 0 07 mm 0 0028 in Thickness Rotor repair limit Standard thickness 10 mm 0 39 in Minimum thickness 9 mm 0 35 in Thickness variation At least 8 portions Maximum 0 02 mm 0 0008 in Assembly 1 Insert cam with depression facing towards open end of cyl inder 2 Generously apply rubber grease to strut and push rod t
20. gt COMBINATION METER ABS WARNING LAMP ABS ACTUATOR AND ELECTRIC UNIT CONTROL UNIT E78 18 23 13 12 TRANSMISSION DATA LINK ABS CONTROL MODULE CONNECTOR Qc ss REFER TO THE FOLLOWING FUSE BLOCK JUNCTION BOX J B FUSE BLOCK JUNCTION BOX J B 213 T4 5 TS TEST Te e Es es eps e ez opes Et JUNCTION BOX 1 2 3 _1415 6 7 8 pra ra napis re 558 YBR229 BR 63 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d BR ABS 03 Refer to EL POWER IGNITION SWITCH ON or START FUSE BLOCK J B E127 m m lt G5 gt With gasoline engine With diesel engine SOLENOID VALVE RELAY ABS ACTUATOR AND ELECTRIC UNIT CONTROL UNIT E78 ACTUATOR IGN MOTOR ACTR MOTOR FL FL FR FR RL PL PR RELAY RELAY MON IN OUT IN OUT IN OUT OUT CONTROL ACT SOL SOL SOL SOL SOL SOL SOL SOL ONIT REFER TO THE FOLLOWING FUSE BLOCK JUNCTION BOX J B YBR230 BR 64 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d ABS ACTUATOR AND ELECTRIC SENSOR SENSOR SENSOR UNIT FR RH FR LH FR LH CONTROL UNIT 21 FRONT WHEEL FRONT WHEEL SENSOR RH SENSOR LH 1 2 3 4 5 6 7 8 9 101112 13 14 15 Yn 4 BR GY B TS YBR231 BR 65 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d ABS ACTUATOR AND EL
21. ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR YBR175 Diagnostic Procedure 2 ABS actuator solenoid valve and solenoid valve relay Malfunction code Nos 41 42 45 46 51 52 55 56 63 for models with self diagnosis function CHECK FUSIBLE LINK Check 40 fusible link g petrol engine fusible link h diesel engine For fusible link layout refer to POWER SUPPLY ROUTING in EL section CHECK FUSE Check 10A fuse 19 For fuse layout refer to POWER SUPPLY ROUTING in NG gt A Go to next page NG _ B Go to next page EL section 1 Disconnect ABS actuator and elec tric unit connector Check terminals for damage or loose connection Then reconnect connector 2 Carry out self diagnosis again Does warning lamp activate NO Inspection end again Yes CHECK ABS ACTUATOR AND ELEC TRIC UNIT GROUND CIRCUIT Refer to ABS ACTUATOR AND ELEC TRIC UNIT GROUND in Ground Circuit NG Repair harness and con nector Check OK CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT 1 Disconnect ABS actuator and elec tric unit connector 2 Check voltage between ABS actua tor and electric unit connector body side terminal and ground Battery voltage should exist NG Check the following e Harness connector E78 e Harness for open or short between ABS ac
22. BELT PRE TENSIONER 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 P11 is as follows The composition varies according to the destination and optional equipment e For a frontal collision The Supplemental Restraint System consists of driver air bag module located in the center of the steering wheel front passenger air bag module located on the instrument panel on passenger side front seat belt pre tensioners a diagnosis sensor unit warning lamp wiring harness and spiral cable e For aside collision The Supplemental Restraint System consists of front side air bag module located in the outer side of front seat side air bag 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 e 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 e Improper maintenance including incorr
23. Bend warning lamp switch plate to ensure e Warning lamp comes on when lever is lifted A notches e Warning lamp goes out when lever is fully released Number of A notches 1 BR 49 ANTI LOCK BRAKE SYSTEM Purpose The Anti Lock Brake System ABS consists of electronic and hydraulic components It allows for control of braking force so that locking of the wheels can be avoided The ABS 1 Provides improved steering control during braking by preventing front wheel lock 2 Provides improved vehicle stability and skid prevention during braking by avoiding rear wheel lock Operation e When the vehicle speed is less than 10 km h 6 mph this system does not work e TheAnti Lock Brake System ABS has self test capabilities The system turns on the ABS warning light for 1 second after turning the ignition switch to the ON position The system performs another test the first time the vehicle reaches 6 km h 4 mph A mechanical noise may be heard as the ABS performs a self test This is a normal part of the self test feature If a malfunction is found during this check the ABS warning light will come on e During ABS operation a mechanical noise may be heard This is a normal operating condition ABS Hydraulic Circuit
24. CAUTION e 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 e Be careful not to deform or bend brake pipes during removal of booster SEC 465 470 Snap pin Gasket 9 e 9 11 17 3 4 1 2 1 7 9 12 P x 1 bw bb ns Clevis pin E mod 4 Brake booster DIM Nm 14 1702 15 9 11 NBR437 BR 18 Output rod length oo 4 E SBR281A Approx 125 127 5 4 92 5 02 Clevis lock nut NBR191 BRAKE BOOSTER Inspection OUTPUT ROD LENGTH CHECK 1 2 3 Supply brake booster with vacuum of 66 7 kPa 667 mbar 500 mmHg 19 69 inHg using hand vacuum pump Add preload of 19 6N 2 0 kg 4 4lb to output rod Check output rod length Specified length 10 275 10 525 mm 0 4045 0 4144 in Installation CAUTION nog Be careful not to deform or bend brake pipes during installation of booster Replace clevis pin if damaged Refill with new brake fluid DOT 4 Never reuse drained brake fluid Take care not to damage brake booster mounting bolt thread when installing Due to the acute angle of installation the threads can
25. Front Rear Wheel Bearing ON VEHICLE SERVICE Go to E in Diagnostic Procedure 8 86 BR 85 TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 7 Unexpected pedal action CHECK BRAKE PEDAL STROKE Yes Perform Preliminar Check brake pedal stroke Is stroke Check refer to 59 excessively large CHECK BRAKE PERFORMANCE SBR540A Disconnect ABS actuator and electric No Perform Preliminar Check refer to BR 50 unit connector and check whether brake is effective Yes CHECK WARNING LAMP ACTIVATE Ensure warning lamp remains off while driving Carry self diagnosis Refer to CHECK WHEEL SENSOR T Repair ABS warning light 1 Check wheel sensor connector for NBR284 terminal damage or loose connec tion 2 Perform wheel sensor mechanical check Refer to Diagnostic Procedure 1 CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals fir damage or the connec tion of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest Diagnostic Procedure 8 Long stopping distance CHECK ABS PERFORMANCE Disconnect ABS actuator and electric unit connector and check whether stop ping distance is still long Yes Perform Preliminary Check and air bleeding Note S
26. MALFUNCTION CODE SYMPTOM CHART BR 76 CHECK FOR ANY SERVICE BULLETINS Not self diagnostic item Self diagnostic item Go to Preliminary ELIMINATE GOOD SYSTEMS AND GOOD PARTS ae DETERMINE MALFUNCTION ING CIRCUIT S OR PART S Self diagnosis Go to Self diagnosis y ELIMINATE GOOD PART S HARNESS ES OR CONNEC TOR S THROUGH ELECTRICALLY TESTING Malfunctioning harness es and Malfunctioning parts connector s v e Go to Diagnostic Procedure s 6 12 85 e Go to Component Parts and Harness Connector Location INSPECTION OF EACH COMPONENT REPAIR REPAIR OR REPLACE NG FINAL CHECK me CHECK OUT BR 58 Go to Diagnostic Pro cedure s 1 5 77 TROUBLE DIAGNOSES Preliminary Check Check brake fluid level in reservoir tank Low fluid level may indicate brake pad wear or leakage from brake line NBR141 Check brake line for leakage Repair Check brake booster for operation and air tightness Refer to Replace Replace Fill up brake fluid Check warning lamp activation When ignition switch is turned on warning lamp turns on Check fuse warning lamp bulb and warning lamp circuit SBRO058C Check warning lamp for dea
27. SBR215B cum Rubber grease Inner diameter 5 022 SMA849B SBR618E REAR DRUM BRAKE Wheel Cylinder Overhaul e Check all internal parts for wear rust and damage Replace if necessary e Pay attention so as not to scratch cylinder when installing pistons Inspection Drum Maximum inner diameter 204 5 mm 8 05 in Maximum out of round 0 03 mm 0 0012 in e Contact surface should be fine finished with No 120 to 150 emery paper e Using a drum lathe resurface brake drum if it shows scoring partial wear or stepped wear e After brake drum has been completely reconditioned or replaced check drum and shoes for proper contact pattern Inspection Lining Check lining thickness Standard lining thickness 4 5 mm 0 177 in Lining wear limit 1 5 mm 0 059 in Installation e ERAT perform shoe clearance adjustment Refer to e 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 Fit toggle lever to brake shoe with retainer ring 2 Apply brake grease to the contact areas shown at left BR 46 REAR DRUM BRAKE Installation Contd 3 Shorten adjuster by rotating it e To tighten loosened brake shoes first insert a screw driver in the direction shown in the left Then
28. begins with the start code 12 After that a maximum of three code numbers appear in the order of the latest one first The indication then returns to the start code 12 to repeat the indica tion will stay on for five minutes at the most The malfunction code chart is given on the next page Example Code No 32 REAR SENSOR SHORT CIRCUIT Start code 12 CODE No 32 Tens digits Units digits Tens digits f yf Units digits ON Warning lamp OFF 0 6 0 6 0 6 0 6 06 0 9 0 310 3 ON 0 3 Unit Second IGN OFF SBR457C Salfdiagnosis completed HOW TO ERASE SELF DIAGNOSTIC RESULTS ABS warning lamp Malfunction codes SR 1 Disconnect the check terminal from ground ABS warning lamp will stay lit 2 Within 12 5 seconds ground the check terminal 3 times Check teria Each terminal ground must last more than 1 second The disconnect ABS warning lamp goes out after the erase operation has Ground 1 TAE been completed 8 mo ape E 3 Perform self diagnosis again Refer to BR 67 Only the start Malfunction code code should appear no malfunction codes memory erased ABR256 BR 68 Trouble Diagnosis General Description CONSULT II CONSULT II APPLICATION TO ABS SELF DIAGNOSTIC ITEM RESULTS DATA MONITOR ACTIVE TEST Front right wheel sensor X Front left wheel sensor Rear right wheel sensor Rear left wheel sensor
29. down pin 11 Retainer ring Piston 7 Plug 12 Return spring Upper Piston cap 8 Brake drum 13 Return spring Lower Spring 9 Shoe hold down spring 14 Spring Wheel cylinder 10 Adjuster 15 Toggle lever Removal WARNING Clean brake lining with a vacuum dust collector to minimize the hazard of airborne materials CAUTION Make sure parking brake lever is completely released BR 44 Toggle lever Shoe hold down spring n Back plate Shoe 4 4 SBR617E 5 020 Adjuster strut Retainer SBR214B SBR330C REAR DRUM BRAKE Removal Cont d LE Release parking brake lever fully then remove drum If drum is hard to remove the following procedures should be carried out Remove plug To make shoe clearance push shoe hold down spring to free toggle lever Install two bolts as shown Tighten the two bolts gradu ally After removing retainer remove spring by rotating shoes Be careful not to damage wheel cylinder piston boots Be careful not to damage parking brake cable when separating it Remove adjuster Disconnect parking brake cable from toggle lever Remove retainer ring with a suitable tool Then separate toggle lever and brake shoe Inspection Wheel Cylinder e Check wheel cylinder for leakage e Check for wear damage and loose conditions Replace if any such condition exists BR 45 bn D Gee
30. move the adjuster in the direction shown by the arrow while disengaging the tooth contact Never tap the area E 4 Connect parking brake cable to toggle lever 5 Install all parts Be careful not to damage wheel cylinder piston boots 6 Check all parts are installed properly Pay attention to direction of adjuster assembly SBR619E 7 Install brake drum 8 When installing new wheel cylinder or overhauling wheel cylinder bleed air Refer to Bleeding Brake System 9 Adjust parking brake Refer to BR 49 BR 47 PARKING BRAKE CONTROL For drum brake SEC 443 9 44 57 n 0 44 0 59 39 51 Rear RH cable 3 2 4 3 0 33 0 44 25 6 38 2 d EN For disc brake 3 2 4 3 0 33 0 44 28 6 38 2 Lock plate 3 2 43 0 33 0 44 28 6 38 2 Lever assembly 15 7 19 6 1 6 2 0 11 6 14 5 Rear LH cable 3 2 4 3 0 33 0 44 28 6 38 2 P Adjusting nut 89 3 2 4 3 0 33 0 44 28 6 38 2 3 2 4 3 0 33 0 44 28 6 38 2 2 43 0 33 0 44 28 6 38 2 Apply grease kg m kg m ft lb 64 00 not re use NBR441 Removal and Installation To remove parking brake cable first remove center console Disconnect warning lamp connector Remove adjusting nut Remove bolts and nuts securing parking brake cable Remove parking brake device
31. or short between ABS actuator and electric unit and fusible link If NG repair harness ro connector CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the con nection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest OK Inspection end n DISCONNECT 8 4 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 5 78 uB OO 1 21 CVT models 22 M T models NBR419 DISCONNECT TS 55 ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 31 E78 YBR186 NG CHECK ABS MOTOR GROUND 1 Turn ignition switch OFF 2 Disconnect ABS actuator and elec tric unit connector 3 Check continuity between ABS actuator and electric unit connector body side terminal and ground Continuity should exist NG Check the following e Harness connector E78 e Harness for open or short between ABS actuator and electric unit and fusible link If NG repair harness ro connector OK REPLACE Replace ABS actuator and electric unit BR 90 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Unit mm in QG16DE QG18DE QG16DE QG18DE and CD20T and CD20T SR20DE For LHD models For RHD models amp Applied model except Wagon Wagon models LHD RHD models models With ABS Without AB
32. or short actuator and electric unit connector between ABS actuator and body side terminal 1 electric unit and fuse If NG repair harness or OK connector Check battery Refer to BATTERY in EL section BR 83 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Diagnostic Procedure 5 Control unit Malfunctioning code No 71 for models with self diagnosis function Fuse ABS actuator and electric unit CHECK CONNECTOR No Inspection end 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose con nections Then reconnect connector 7 NM 2 Carry out self diagnosis again Does warning lamp activate again ABS control unit YBR182 Yes ABS CONTROL UNIT POWER SUPPLY CHECK Check voltage Refer to in Diagnostic Procedure 4 CHECK SELF DIAGNOSTIC RESULTS Yes Replace ABS actuator and Does warning lamp indicate code No 71 electric unit again INSPECTION Inspect the system according to the code No BR 84 TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 6 ABS works frequently CHECK WHEEL SENSOR NG Perform Preliminary check 1 Check wheel sensor connector for termi Refer to nal damage or loose connections 2 Perform wheel sensor mechanical check Refer to Diagnostic Procedure 1 BR 77 Check front axles for excessive looseness Refer to FA and RA section
33. 74 It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly In this case suspend cylinder body with wire so as not to stretch brake hose Burnish the brake contact surfaces after refinishing or replacing rotors after replacing pads or if a soft pedal occurs at very low mileage Refer to Brake Burnishing Procedure CHECK AND ADJUSTMENT Remove master cylinder reservoir cap Remove brake cable mounting bolt and lock spring Release parking brake control lever then disconnect cable from the caliper Remove upper pin bolt Open cylinder body downward Then remove pads inner and outer shims Standard pad thickness 9 3 mm 0 366 in Pad wear limit 2 0 mm 0 079 in When installing new pads push piston into cylinder body by gently turning piston clockwise as shown Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston Adjust the piston to the right angle as shown in the figure BR 34 REAR DISC BRAKE TYPE 1 Concave portion NBR375 SBR646 SBR889 Pad Replacement Cont d 8 As shown in the figure align the piston s concave to the pad s convex then install the cylinder body to the torque member 9 Install brake cable brake cable mounting bolt lock spring and master cylinder reservoir cap Removal WARNING Clean brake pads with a vacuum dus
34. 822BA Brake fluid pressure gauge SBR823BA NBR145 CONTROL VALVE Dual Proportioning Valve INSPECTION CAUTION Applied pressure Front brake Output pressure Rear brake Carefully monitor brake fluid level at master cylinder Use new brake fluid DOT 4 Be careful not to splash brake fluid on painted areas it may cause paint damage If brake fluid is splashed on paint areas wash it away with water immediately Depress pedal slowly when raising front brake pressure Check rear brake pressure at least 2 seconds after front brake pressure reaches specified value Connect brake fluid pressure gauge to air bleeders of front and rear brakes on either LH or RH side Bleed air from the tool Check fluid pressure by depressing brake pedal Unit kPa bar kg cm psi 5 39 53 9 55 781 6 3 132 3 532 31 32 35 32 31 94 36 02 454 3 512 3 If output pressure is out of specifications replace dual pro portioning valve 4 Bleed air after disconnecting the Tool Refer to Bleeding Brake System REMOVAL CAUTION e 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 e All tubes must be free from excessive bending twisting and pulling 1 Connect a vinyl tube to air bleeder valve 2 Drain brake fluid from each air bleeder valve by depr
35. BR 26 FRONT DISC BRAKE Pad Replacement Cont d Torque member lug Locating holes Torque member lug NBR292 REMOVAL 1 Remove the housing retaining spring SR20DE M T 2 Wipe away any dirt from the guide pins between the torque member and the cylinder body Protective NBR300 Wire NBR290 3 Pull out the protective caps from the guide sleeves 4 Use a 7 mm ALLEN key to unscrew the guide pins from the torque member 5 Partially remove the guide pins from the guide sleeve 6 Pull the cylinder body manually towards the outer side of the vehicle so that the piston is slightly pressed back 7 Remove the cylinder body and hang it on a wire in the wheel arch in a suitable position Make sure there is no strain on the brake hose piping 8 Remove the brake pad on the piston side from the piston 9 Remove the second brake pad from the torque member BR 27 Wire Cylinder body Guide groove Second brake pad Three pronged brake pad NBR303 kg m ft lb J Protective caps NBR299 FRONT DISC BRAKE Pad Replacement Cont d CAUTION Do not use any sharp tools or cleaning agents which con tains mineral oil Damage to the installation can occur 10 Clean the cylinder body and guide grooves in the torque member 11 Check the dust cover and guide sleeves for damage 12 Measure the amount of wear on
36. ECTRIC SENSOR SENSOR SENSOR UNIT RR RH RR LH RR LH CONTROL UNIT E78 PU LG Y BR 05 409 857 LG Y BR REAR WHEEL REAR WHEEL SENSOR RH SENSOR LH 2 3 L 31 4 5 6 7 8 910 11 1213 14 18 1 YBR232 BR 66 TROUBLE DIAGNOSES DATA link connector for CONSULT II CY Ground terminal 8 with a suitable harness RRS p NBR295 ABS warning light NBR284 DATA link connector for CONSULT II 8 Disconnect the har ness NBR305 Self diagnosis Only models with data link connector terminal No 8 FUNCTION e When a problem occurs in the ABS the warning lamp on the instrument panel comes on To start the self diagnostic results mode ground the self diagnostic check terminal located on Data Link Connector for CONSULT II The loca tion of the malfunction is indicated by the warning lamp flash ing SELF DIAGNOSIS PROCEDURE Drive vehicle over 30 km h 19 mph for at least one minute _____ ______ Turn ignition switch to the LOCK position Ground terminal 8 of DATA LINK CON NECTOR for CONSULT II with a suitable harness Turn ignition switch to ON position while grounding terminal 8 Do not depress brake peda
37. IC UNIT GROUND in Ground Circuit Check 75 OK REPLACE Replace ABS actuator and electric unit BR 81 NG Repair harness and termi nals TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Diagnostic Procedure 3 Motor Relay or DISCONNECT ABS ACTUATOR AND ELECTRIC UNIT AND CONNECTOR YBR179 motor Cont d 9 REPLACE Inspection end Replace fusible link Does the fusible link blow out when ignition switch is turned ON CHECK ABS ACTUATOR MOTOR NG Check the following POWER SUPPLY CIRCUIT e Harness connector 1 Disconnect battery cable and ABS E78 actuator and electric unit connector e Harness for open or E78 short between ABS 2 Check continuity between ABS actuator and electric actuator and electric unit connector unit and fusible link body side terminal and If NG repair harness ro ground connector Continuity should not exist 55 Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit har ness connector Reconnect ABS actuator and electric unit harness connector Then retest BR 82 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Diagnostic Procedure 4 Low voltage Fuse 19 ENHA ABS actuator and electric unit Malfunction code No 57 for models with
38. In this case suspend cylinder body with wire so as not to stretch brake hose e Burnish the brake contact surfaces after refinishing or replacing rotors after replacing pads or if a soft pedal occurs at very low mileage Refer to Brake Burnishing Procedure ON VEHICLE SERVICE BR 40 REAR DISC BRAKE TYPE 2 SBR641 NBR374 NBR375 Pa 1 Replacement Remove master cylinder reservoir Remove brake cable lock spring Release parking brake control lever then disconnect cable from the caliper Remove upper pin bolt Open cylinder body downward Then remove pad inner and outer shims Standard pad thickness 9 3 mm 0 366 in Pad wear limit 2 0 mm 0 079 in When installing new pads push piston into cylinder body by gently turning piston clockwise as shown Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston Adjust the piston to the right angle as shown in the figure As shown in the figure align the piston s concave to the pad s convex then install the cylinder body to the torque member Install brake cable brake cable mounting bolt lock spring and master cylinder reservoir cap BR 41 REAR DISC BRAKE TYPE 2 Removal WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials 1 Remove brake cabl
39. NE AIR BAG MALFUNCTION REPAIR Make the necessary repairs following the diagnostic procedures C2SSE01 After repairing the malfunctions erase the self diagnostic results stored in the control unit by touching ERASE D SELECT DIAG MODE SELF DIAG RESULTS DATA MONITOR ACTIVE TEST Check warning lamp for deactivation after driving vehicle over 30 km h 19 mph for at least one minute ECU PART NUMBER C2SDM01 SELF DIAG RESULTS DTC RESULTS Note SELF DIAG RESULTS screen shows the detected malfunction and the times of ignition switch on and off after it occurred FR RH SENSOR OPEN C2SDR01 BR 70 Trouble Diagnosis General Description CONSULT II Inspection Procedure Cont d SELF DIAGNOSTIC RESULTS MODE Diagnostic item FR RH SENSOR OPEN FR LH SENSOR OPEN Diagnostic item is detected when e Circuit for front right wheel sensor is open An abnormally high input voltage is entered e Circuit for front left wheel sensor is open An abnormally high input voltage is entered Diagnostic procedure RR RH SENSOR OPEN Circuit for rear right sensor is open An abnormally high input voltage is entered RR LH SENSOR OPEN e Circuit for rear left sensor is open An abnormally high input voltage is entered FR RH SENSORx SHORT FR LH SENSOR SHORT RR RH SENS
40. NY YOLWALOV 7041405 6 1 133HM LNOH4 NOILVNISWOO 1 5 Hd 133 14093 0123 02 me NOLIN ANIT VIVO I8NOO 8l 97 04 U09 4015514454221 WoL X LYVLS 10 NO AMALLV HOLIMS ANIT ANT 3181513 3181504 BR 61 TROUBLE DIAGNOSES Wiring Diagram ABS MODELS WITH SELF DIAGNOSIS FUNCTION BR ABS 01 IGNITION SWITCH FUSE BLOCK a Refer to EL POWER LG R QD LHD models lt C gt CVT models QR RHD models M T models STOP LAMP B 1 lt gt 2 lt C gt SWITCH D 4 Tam COMBINATION METER ABS WARNING LAMP 459 BD B ABS ACTUATOR B AND ELECTRIC UNIT CONTROL UNIT 28 E78 STOP LAMP Sw p GRO 8 TRANSMISSION CON DATA LINK CON TROL MODULE NECTOR Refer to las page Foldout page Lisa Lp e repo as s 35 6 137 38 39 0 2 3 4 5 6 78 9 ENS E127 BAB e rata YBR208 BR 62 TROUBLE DIAGNOSES Wiring Diagram ABS Cont d MODELS WITHOUT SELF DIAGNOSIS FUNCTION IGNITION SWITCH ON or START BATTERY BR ABS 02 Refer to EL POWER LGR L gt LHD models lt C gt models RHD models M T models 1 lt gt 1G lt R gt 2B STOP LAMP SWITCH Gm lt
41. OR SHORT e Circuit for front right wheel sensor is shorted An abnormally low input voltage is entered e Circuit for front left wheel sensor is shorted An abnormally low input voltage is entered Circuit for rear right sensor is shorted An abnormally low input voltage is entered RR LH SENSOR SHORT Circuit for rear left sensor is shorted An abnormally low input voltage is entered ABS SENSOR ABNORMAL SIGNAL e Teeth damage on sensor rotor or improper installation of wheel sensor Abnormal wheel sensor signal is entered FR RH IN ABS SOL OPEN e Circuit for front right inlet solenoid valve is open An abnormally low output voltage is entered FR LH IN ABS SOL OPEN RR RH IN ABS SOL OPEN RR LH IN ABS SOL OPEN e Circuit for front left inlet solenoid valve is open An abnormally low output voltage is entered e Circuit for rear right inlet solenoid valve is open An abnormally low output voltage is entered e Circuit for rear left inlet solenoid valve is open An abnormally low output voltage is entered FR RH IN ABS SOL SHORT e Circuit for front right inlet solenoid valve is shorted An abnormally high output voltage is entered FR LH IN ABS SOL SHORT e Circuit for front left inlet solenoid valve is shorted An abnormally high output voltage is entered RR RH IN ABS SOL SHORT RR LH IN ABS SOL SHORT FR RH OUT ABS SOL OPEN e Ci
42. On vehicle Service 3 Change relative positions of rotor and wheel hub so that runout is minimized Maximum runout 0 07 mm 0 0028 in Thickness Rotor repair limit Standard thickness 10 mm 0 39 in Minimum thickness 9 mm 0 35 in Thickness variation At least 8 portions Maximum 0 02 mm 0 0008 in Installation CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid e Do not drain factory filled brake fluid from new cali per assemblies 1 Install caliper assembly e As shown in the figure align the piston s concave to the pad s convex then install the cylinder body to the torque member 2 Remove the plug from the cylinder body and brake hose CAUTION Care should be taken as not to let e Air enter the cylinder body and brake hose Brake fluid spill from the cylinder body and brake hose Install brake hose to caliper securely Install all parts and secure all bolts Bleed air Refer to Bleeding Brake System 8 oc ROS BR 43 REAR DRUM BRAKE Components SEGAN i 6 9 10 1 0 70 1 03 61 89 SD 9 4 4 5 7 0 44 0 59 39 51 5 9 8 8 bean 0 6 0 9 52 78 C 9 m e 2 Eo AC zc T 4 2 43 54 4 3 5 6 32 40 9 i kg m in ib d Nem kg m ft lb p d 2 ee Rubber grease point Brake grease point o c SBR616E Boot 6 Shoe hold
43. S optional for With ABS LHD models Front brake CL25VG CL25VBG FN3 57 22 Brake model disc brake disc brake disc brake Cylinder bore diameter 57 2 2 252 Pad length x width x thickness 109 x 50 1 x 11 94 29 x 1 97 x 0 43 112 x 56 2 x 11 4 41 x 2 21 x 0 43 109 x 50 1 x 11 4 29 x 1 97 x 0 43 Rotor outer diameter x thickness Rear brake 257 x 22 10 12 x 0 87 CL9HCG LT20N 280 x 22 11 04 x 0 87 CL9HDG CL11HEG Brake model disc brake drum brake disc brake disc brake 34 4 1 354 17 46 0 6874 ae 38 2 1 504 1 354 Lining or pad 79 8 38 5 x 9 3 195 35 x 4 5 length x width x thickness 3 14 x 1 52 x 7 68 x 1 38 x ae 0 37 0 18 5 inner diameter rotor 258 x 10 800 278 x 10 258 x 10 10 2 x 0 39 10 9 0 39 10 2 0 39 Diameter thickness Master cylinder Cylinder bore diameter Control valve Valve model Dual proportioning valve 23 81 0 94 Split point kPa bar kg cm psi x reducing ratio Brake booster Booster model 1 96 0 0196 0 0200 0 284 x 0 4 BJKCE Diaphragm diameter Specified brake fluid BR 91 Primary 205 8 1 Secondary 180 7 1 DOT 4 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment DISC BRAKE Unit mm in CL25VG CL25VBG FN3 57 22 CL9OHCG CL9HDG Pad wear limit Minimum thi
44. SEC 440 e Ser 3 9 32 3 3 8 23 28 Stopperibelt e G 10 12 ek 9 1 0 1 2 7 9 amp Eo e RU Cb 22 32 in a 9 to sliding portion 6 Do not re use Nem kg m ft b 38 52 8 Rubber grease point 3 9 5 3 28 38 Brake fluid point PBC Poly Butyl Cuprysil grease or silicone based grease point NBR366 1 Cable guide 11 Strut 21 Washer 2 Cylinder 12 O ring 22 Wave washer 3 Toggle lever 13 Push rod 23 Washer 4 Pin 14 Key plate 24 Bearing 5 Pin boot 15 Retaining washer 25 Adjuster 6 Torque member 16 Spring 26 Cup 7 Inner shim 17 Spring cover 27 Piston 8 Inner pad 18 Snap ring B 28 Piston boot 9 Outer pad 19 Piston seal 29 Sleeve 10 Outer shim 20 Snap ring A Pad Replacement WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials CAUTION e When cylinder body is open do not depress brake pedal because piston will pop out e Becareful not to damage piston boot or get oil on rotor Always replace shims in replacing pads e If shims are rusted or show peeling of rubber coat replace them with new shims BR 33 REAR DISC BRAKE TYPE 1 Pad Replacement Cont d SBR641 Assembly to the right angle Alignment position of disc pad s concave NBR3
45. TS ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 11 9 14 7 _ 12 10 15 8 A NBR414 s Xa DISCONNECT TS Front E17 Rear nsor sensor senso 2110 211 al al YBR173 INSPECTION STARTS 1 Disconnect connectors from ABS actuator and electric unit and wheel sensor of malfunction code No Check terminals for damage or loose connections Then reconnect con nectors 2 Carry out self diagnosis again Does warning lamp activate again NO Inspection end Yes CHECK WHEEL SENSOR ELECTRI CAL 1 Disconnect ABS actuator and electric unit connector 2 Check resistance between ABS actuator and electric unit connector body side terminals Code No 21 or 22 Front RH wheel Terminals 1 2 Code No 25 or 26 Front LH wheel Terminals and Code No 31 or 32 Rear RH wheel Terminals 3 and 5 Code No 35 or 36 Rear LH wheel Terminals 7 and Resistance Front 1 44 1 76 Rear 1 44 1 76 CHECK WHEEL SENSOR Check each sensor for resistance Resistance Front 1 44 1 76 ko Rear 1 44 1 76 kQ OK gt A Go to next page Check the following e Harness connectors E78 e Harness for open or short between wheel sensor connectors and ABS actuator and electric unit If NG repair harness or connectors REPLACE Replace wheel sensor BR 77 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Diagnostic Proc
46. as described in page 73 SELECT DIAG MODE SELF DIAG RESULTS DATA MONITOR ACTIVE TEST ECU PART NUMBER C2SDM01 SELECT MONITOR ITEM ALL SIGNALS SELECTION FROM MENU C2SMI01 BR 72 Trouble Diagnosis General Description CONSULT II Inspection Procedure Cont d DATA MONITOR MODE MONITOR ITEM CONDITION SPECIFICATION FR RH SENSOR FR LH SENSOR REAR RH SENSOR REAR LH SENSOR STOP LAMP SW Drive vehicle Each wheel is rotating Brake is depressed Wheel speed signal Almost the same speed as speedometer Depress the pedal ON Release the pedal OFF FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL RR RH IN SOL RR RH OUT SOL RR LH IN SOL RR LH OUT SOL Drive vehicle at speeds over 30 km h 19 mph for at least one minute Engine is running MOTOR RELAY Operating conditions for each solenoid valve are indicated ABS is not operating OFF ABS is not operating OFF ABS is operating ON ACTUATOR RELAY WARNING LAMP Ignition switch is set to the ON position or engine is running BATTERY VOLT Ignition switch in the ON position Engine stops OFF Engine running ON Warning lamp is turned on ON Warning lamp is turned off OFF Power supply voltage for control unit BR 73 Trouble Diagnosis General Description NISSAN CONSULTI AED99A START SUB MODE C2NCS01 ENGINE
47. be damaged on the metal surrounding the dash panel holes Before fitting booster temporarily adjust clevis to dimension shown in the table Adjustment mm in LHD 127 5 5 02 RHD 125 4 92 Fit booster then secure mounting nuts brake pedal bracket to booster lightly Connect brake pedal and booster input rod with clevis pin Secure mounting nuts Specification 11 17 N m 1 2 1 7 kg m 9 12 ft lb Install master cylinder Refer to BE 14 Bleed air Refer to Bleeding Brake System 8 Adjust pedal height to specification Refer to SDS 92 Retighten clevis locknut Specification 16 22 N m 1 6 2 2 kg m 12 16 ft lb BR 19 VACUUM HOSE LHD Petrol models RHD Petrol models Diesel models Vacuum reservoir To brake booster Vacuum hose aw Re UU Check valve AN 220 os B PN To Intake manifold gh gt Ee 5 Check To Brake booster NBR421 BR 20 VACUUM HOSE Removal and Installation umm e CAUTION 4 LJ When installing vacuum hoses pay attention to the follow More than 24 mm ing points 0 94 in e Do not apply any oil or lubricants to vacuum hose and check valve e Insert vacuum tube into vacuum hose as shown Connect hose until it contacts pro trusion on vacuum
48. ccepts input signals from sensors and utilises the data to instantly drive the actuators It is essential that both input and output signals are correct and stable It is also important to check for conventional problems such as air leaks in booster lines lack of brake fluid or other problems with the brake system It is much more difficult to diagnose a problem that occurs inter mittently rather than catastrophically Most intermittent problems are caused by poor electric connections or faulty wiring In this case careful checking of suspicious circuits may help prevent the unnecessary replacement of good parts A visual check may not be sufficient to find the cause of the problems so a road test should also be performed Before undertaking actual checks take just a few minutes to talk with a customer who approaches with a ABS complaint The customer is a very good source of information on such problems especially intermittent ones Through the talks with the customer find out what symptoms are present and under what conditions they occur Start your diagnosis by looking for conventional problems first This is one of the best ways to troubleshoot brake problems on an ABS controlled vehicle BR 57 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair Cont d WORK FLOW LISTEN TO CUSTOMER COMPLAINTS INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELARED TO EACH SYMPTOM AND NOTE Go to
49. ckness 2 0 0 079 Rotor repair limit 20 0 20 0 20 0 9 0 9 0 9 0 Minimum thickness 0 787 0 787 0 787 0 354 0 354 0 354 Maximum runout 0 07 0 0028 Maximum thickness variation 0 02 0 0008 DRUM BRAKE Unit mm in Brake model LT20N Lining wear limit Minimum thickness 1 5 0 059 Maximum inner diameter 204 5 8 051 Drum repair limit Maximum out of round 0 03 0 0012 BRAKE PEDAL Unit mm in Applied model RHD LHD Free height M T 160 170 6 30 6 69 151 161 5 94 6 34 CVT 169 179 6 65 7 05 160 170 6 30 6 69 Depressed height under force of 490 N 50 kg 110 Ib M T 80 90 3 15 3 54 71 81 2 80 3 19 withenginerunning CVT 89 99 3 50 3 90 80 91 3 15 3 54 PARKING BRAKE CONTROL Control type Center lever Number of notches under force of 196 N 20 kg 44 Ib Number of notches when warning switch comes on BR 92
50. ctivation Go to Self diagnosis When ignition switch is turned on and warning lamp turns on then deacti vates after 1 second ee Drive vehicle at 30 km h 19 mph for Qt at least one minute SBRO59C Ensure warning lamp remains off while NG Self diagnosis driving and OK END ABS warning light NBR284 BR 59 TROUBLE DIAGNOSES Component Parts and Harness Connector Location Warning light Brake tube connector ABS actuator and electric unit Rear wheel sensors Rear left wheel sensor connector Rear right wheel sensor connector E Front wheel sensors Front left wheel sensor connector D Front right wheel sensor connector 2 Rear left wheel sensor connector paar tir Rear right wheel IV sensor connector NBR285 BR 60 TROUBLE DIAGNOSES int Check inpo t Diagram for Quick Pi ircui C YBR228 zs 0S48vS0fll Ld NIA 49342 S PON 051876011 Ld NIA 94939q sisoubeip Jjas OSZL8PSONL Ld NIA 94038q s epouu L W 08487950 Ld NIA 4938 S epouu pue 04 8 50 114 941039q 5 AD 9 0000 A 8 2 iion 3 x 2 O T33HM 133HM 21819313 A
51. cure rotor to wheel hub with at least two nuts M12 x 1 25 2 Check runout using a dial indicator Make sure that wheel bearing axial end play is within the specifications before measuring Refer to section FA Maximum runout 0 07 mm 0 0028 in 3 If the runout is out of specification find minimum runout posi tion as follows a Remove nuts and rotor from wheel hub b Shift the rotor one hole and secure rotor tho wheel hub with nuts c Measure runout d Repeat steps a to c so minimum runout position can be found 4 Ifthe runout is still out of specification turn rotor with on car brake lathe DL 8700 700 and 705 or equivalent THICKNESS Rotor repair limit Standard thickness 22 mm 0 87 in Minimum thickness 20 0 mm 0 787 in Thickness variation At least 8 positions Maximum 0 02 mm 0 0008 in Assembly CAUTION Always use new piston seal 1 Insert new piston seal into groove in cylinder body 2 With dust seal fitted to piston insert dust seal into groove on cylinder body and install piston 3 Properly secure dust seal BR 31 FRONT DISC BRAKE NBR298 Installation CAUTION Refill with new brake fluid DOT 4 Never reuse drained brake fluid Install brake hose to caliper securely Install all parts and secure all bolts Bleed air Refer to Bleeding Brake System BR 8 BR 32 REAR DISC BRAKE TYPE 1 Component
52. e 79 Diagnostic Procedure 3 Motor Relay or motor 81 Diagnostic Procedure 4 Low voltage 83 Diagnostic Procedure 5 Control unit 84 TROUBLE DIAGNOSES FOR SYMPTOMS 85 Diagnostic Procedure 6 ABS works frequently 85 Diagnostic Procedure 7 Unexpected pedal Te ilo 86 Diagnostic Procedure 8 Long stopping distance 86 Diagnostic Procedure 9 ABS does not work 87 Diagnostic Procedure 10 Pedal vibration and NOISE 87 Diagnostic Procedure 11 ABS Warning lamp does not come on when ignition switch is turned ON sess tco c Eu e ea 88 Diagnostic Procedure 12 Warning lamp stays on when ignition switch is turned ON 90 SERVICE DATA AND SPECIFICATIONS SDS 91 General 91 Inspection and Adjustment 92 e Read section HOW TO READ WIRING DIAGRAMS e See EL section POWER SUPPLY ROUTING for power distribution circuit e See EL section for NATS information and wiring diagram When you perform trouble diagnoses read section HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT BR 2 PRECAUTIONS Supplemental Restraint System SRS AIR BAG and SEAT
53. e 3 Drain brake fluid from each air bleeder valve depressing brake pedal to empty fluid from master cylinder 4 Remove brake pipe flare nuts 5 Remove master cylinder mounting nuts Disassembly 1 Drive out elastic pin from cylinder body 2 Remove reservoir tank and seals SBR231E BR 15 Piston stop per pin SBR232E Secondary piston Primary piston SBR233E Piston stop per pin SBR232E MASTER CYLINDER Disassembly Cont d 3 Remove the circlip with suitable pliers while piston is pushed into cylinder 4 Remove piston stopper pin while piston is pushed into cylin der 5 Remove piston assemblies If it is difficult to remove secondary piston assembly gradually apply compressed air through fluid outlet Inspection Check for the following items Replace any part if damaged Master cylinder e Pin holes or scratches on inner wall Piston e Deformation of or scratches on piston cups Assembly 1 Insert secondary piston assembly Then insert primary piston assembly e Pay attention to alignment of secondary piston slit with valve stopper mounting hole of cylinder body 2 Install piston stopper pin while piston is pushed into cylinder Then secure the primary and secondary piston assemblies with new circlip 3 Push reservoir tank seals and reservoir tank into cylinder body 4 Install elastic pin BR 16 es
54. e Booster ABS actuator and electric unit Brake tube connector Master cylinder n Primary line Secondary line NBR434 BR 9 BRAKE HYDRAULIC LINE SBR419C Commercial service tool SBR686C Removal 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 and tubes must be free from excessive bending twisting and pulling For rear disc caliper care should be taken as not to let air enter the body Connect a vinyl tube to air bleeder valve 2 Drain brake fluid from each air bleeder valve by depressing brake pedal 3 Remove flare nut securing brake tube to hose then withdraw lock spring 4 Cover openings to prevent entrance of dirt whenever discon necting hydraulic line Inspection Check brake lines tubes and hoses for cracks deterioration or other damage Replace any damaged parts Installation CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid 1 Tighten all flare nuts and connecting bolts Flare nut 15 18 N m 1 5 1 8 kg m 11 13 ft Ib Connecting bolt 01 17 20 1 7 2 0 kg m 12 14 ft Ib 2 Refill until new brake fluid comes out of each air bleeder valve 3 Bleed air Refer to Bleeding Brake System BR 8 BR 10 Brake fluid pressure SBR
55. e lock spring 2 Release parking brake control lever then disconnect cable from the caliper 3 Remove torque member fixing bolts and connecting bolt 4 Remove brake hose connecting bolt 5 Plug off the brake hose and cylinder body to prevent air entering the system NBR427 CAUTION Care should be taken as not to let e Air enter the cylinder body and brake hose e Brake fluid spill from the cylinder body and brake hose Disassembly Remove pin bolts and pins NOTE Cylinder body can not be disassembled Inspection CALIPER CAUTION Do not drain any brake fluid from cylinder body Cylinder body can not be disassembled Cylinder Body Check cylinder body for score rust wear damage or presence of foreign materials If any of the above conditions are observed replace cylinder body Torque Member Check for wear cracks or other damage Replace if necessary Pin and Pin Boot Check for wear cracks or other damage Replace if any of the above conditions are observed BR 42 REAR DISC BRAKE TYPE 2 SBR219C NBR374 NBR375 Inspection Cont d ROTOR Rubbing Surface Check rotor for roughness cracks or chips Runout 1 Secure rotor to wheel hub with two nuts M12 x 1 25 2 Check runout using a dial indicator Make sure that axial end play is within the specifications before measuring Refer to AX section REAR WHEEL BEARING
56. ect 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 e Do notuse 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 e Recommended fluid is brake fluid DOT 4 e Never reuse drained brake fluid e Becareful not to splash brake fluid on painted areas e Toclean or wash all parts of master cylinder disc brake caliper and wheel cylinder use clean brake fluid e Never use mineral oils such as gasoline or kerosene They will ruin rubber parts of the hydraulic system EE flare nut wrench when removing and installing brake ube e Always torque brake lines when installing e Burnish the brake contact surfaces after refinishing or replacing rotors after replacing pads or if a soft pedal occurs at very low mileage Refer to Brake Burnishing Procedure Check and Adjustment WARNING e Clean brake pads with a waste cloth then wipe with a dust collector BR 3 POWER SUPPLY ROUTING PRECAUTIONS Precautions When Working On ABS Use recommended tyres in combination with ABS Install tyres or studded tyres
57. edure 1 Wheel sensor or OK 5 rotor Cont d Front sensor Qe Feeler gauge a N Note Note 2 CHECK TYRE NG Adjust tyre pressure or Check for inflation pressure wear and replace tyre s size of each tyre o i Note CHECK WHEEL BEARING Check wheel bearing axial end play and Clean sensor fixing portion or replace sensor clearance between sensor and rotor Clearance Front 0 1 1 1 mm 0 004 0 043 in Rear 0 536 1 551 mm 0 021 0 061 in NBR391 Note Check sensor rotor for teeth damage OK CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit har ness connector Reconnect ABS actuator and electric unit harness connector Then retest CHECK SENSOR ROTOR NG Replace sensor rotor Note Wheel position should be indentified by code num bers except code No 18 sensor rotor BR 78 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS EMHI Fusible link F1 1 9 ABS actuator and electric unit Fuse 19 FL_IN amp p Solenoid valve relay 99 ABS control unit ABS actuator and electric unit connector lt GS gt With petrol engine With diesel engine YBR174 DISCONNECT 59 TS
58. essing brake pedal 3 Loosen flare nut 4 Remove proportioning valve mounting bolt then remove flare nut BR 11 CONTROL VALVE Dual Proportioning Valve Cont d INSTALLATION CAUTION e Refill with new brake fluid DOT 4 e Never reuse drained brake fluid 1 Temporarily fit flare nut to proportioning valve 2 Tighten proportioning valve mounting bolt then tighten flare nut with wooden block placed between proportioning valve and dash panel Flare nut 15 18 N m 1 5 1 8 kg m 11 13 ft Ib Mounting bolt kg 5 1 8 8 N m 0 52 0 9 kg m 45 78 in Ib 3 Refill until new brake fluid comes out of each air bleeder valve 4 Bleed air Refer to Bleeding Brake System BR 8 BR 12 BRAKE PEDAL AND BRACKET Removal and Installation Petrol models Diesel models Redundant brake switch Brake lamp switch e 2 79 Citi T Clevis pin O 11 17 1 2 1 7 9 12 Brake lamp switch O N m kg m ft b NBR435 Inspection Stopper Check brake pedal for following items e Brake pedal bend e Clevis pin deformation e Crack of any welded portion e Crack or deformation of clevis stopper SBR997 Clevis lock nut Adjustment 15502 ton Check brake pedal free height from dash reinforcement panel Input rod Free height Refer to SDS 92 Brake lamp switch D Depressed height and redundant Refer to SDS brake s
59. etc with the same size If different sizes of tyres or tyres other than the ones recommended for use with the ABS are fitted stopping distance will increase and control and stability could deteriorate When changing brake pads use Nissan genuine parts When fitting radios etc do not position the radio unit antenna or antenna cables within an area of about 100 mm 3 94 in of the control unit When doing any work that requires electro welding first remove the control unit Make sure when taking a power supply for the audio lamps etc not to take this from any ABS related har ness Refer to the electrical wiring diagrams for ABS related harnesses Wiring Diagrams and Trouble Diagnosis When you read wiring diagrams refer to the following GI 11 HOW TO READ WIRING DIAGRAMS When you perform trouble diagnosis refer to the following e HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS HOW TO PERFORM EFFICIENT DIAGNOSES FOR AN ELECTRICAL INCIDENT BR 4 PRECAUTIONS AND PREPARATION Commercial Service Tools Tool name Description Flare nut crows foot Removing and installing each brake piping Torque wrench Sa So 0 2 1 NT360 a 10 mm 0 39 in Brake fluid pressure Measuring brake fluid pressure gauge NT151 BR 5 9 x SLYVd 1919394518 pue esneo e gissog eoueJeJeu exeus Pads damaged
60. id e 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 2 Connect a vinyl tube to each air bleeder valve 3 Drain brake fluid from each air bleeder valve by depressing brake pedal while keeping reservoir level higher than mini mum line by adding new brake fluid 4 Repeat until new 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 Burnish the brake contact surfaces according to the following procedure after refinishing or replacing rotors after replacing pads 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 BR 7 CHECK AND ADJUSTMENT Brake Burnishing Procedure Cont d SBR995 SBR419C 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 pressure such that vehicle stopping time equals 3 to 5 seconds To cool the brake system drive the vehicle at 50 km h 31 MPH for 1 minute without stopping Repeat steps 1 to 3 10 times or m
61. l After 3 0 seconds the warning lamp starts flashing to indicate the malfunction code No See NOTE rr Ss Verify the location of the malfunction with the malfunction code chart Refer to Then make the necessary repairs following the diagnostic procedures After the malfunctions repaired erase the malfunction codes stored in the control unit Refer to Rerun the self diagnostic results mode to verify that the malfunction codes have been erased NOTE The indication ter Disconnect the check terminal from the minates after five minutes ends TT results mode is However when the ignition switch is Y turned from off to on the indication starts flashing again BR 67 TROUBLE DIAGNOSES Self diagnosis Only models with data link connector terminal No 8 Cont d Check warning lamp for deactivation after driving vehicle over 30 km h 19 mph for at least one minute After making certain that warning lamp does not come on test the ABS in a safe area to verify that it functions properly HOW TO READ SELF DIAGNOSTIC RESULTS Malfunction codes e Determine the code No by counting the number of times the warning lamp flashes on and off e When several malfunctions occur at one time up to three code numbers can be stored the latest mal function will be indicated first The indication
62. necting bolt except for disassembly or replacement of caliper assembly Disassembly WARNING Do not place your fingers in front of piston CAUTION Do not scratch or score cylinder wall 1 Push out piston with dust seal with compressed air 2 Remove piston seal with a suitable tool NBR294 Inspection Caliper CYLINDER BODY e Check inside surface of cylinder for score rust wear dam age or presence of foreign materials If any of the above conditions are observed replace cylinder body e Minor damage from rust or foreign materials may be elimi nated by polishing surface with a fine emery paper Replace cylinder body if necessary CAUTION Use brake fluid to clean Never use mineral oil BR 29 FRONT DISC BRAKE Inspection Caliper Cont d PISTON CAUTION Piston sliding surface is plated Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface Check piston for score rust wear damage or presence of for eign materials Replace if any of the above conditions are observed GUIDE PIN BOLT AND RETAINING SPRING Check for wear cracks or other damage Replace if any of the above conditions are observed BR 30 SBR936A SBR944A Dust seal Piston seal Se Cylinder body SBR574 FRONT DISC BRAKE Inspection Rotor RUBBING SURFACE Check rotor for roughness cracks or chips RUNOUT 1 Se
63. o make insertion easy BR 37 REAR DISC BRAKE TYPE 1 Assembly Cont d Key plate cE2 Push rod Rod 4 SBR893 Ring B 3 Spring cover ont Spring Retaining washer tool Ring B Spring cover 50 6 Ji gt Spring 5 9 Retaining washer Adjusting nut SBR892 3 4 5 6 Install rod push rod and key plate Fit push rod into square hole in key plate Also match con vex portion of key plate with concave portion of cylinder Install retaining washer spring spring cover and snap ring B with suitable press and drift Install cup in the specified direction BR 38 REAR DISC BRAKE TYPE 1 Assembly Cont d Ring 7 Install cup adjuster bearing washers and snap ring A with a Washer suitable tool Wave washer amp Washer Ball bearing Adjuster 8 Cup Piston b 2 8 Insert piston seal into groove on cylinder body 9 With piston boot fitted to piston insert piston boot into groove on cylinder body and fit piston by turning it clockwise with long nose pliers or suitable tool 2 SBR646 10 Fit toggle lever return spring and cable guide SBR767E 11 Adjust the piston to the right angle as shown in the figure Assembly Alignment position of to the right disc pad s concave angle NBR374
64. observed BR 25 FRONT DISC BRAKE SEC 440 Connecting bolt 17 20 Bleed valve 1 7 2 0 12 14 Guide 5 7 Three pronged pin 0 6 0 7 45 61 brake pad Torque member 7 fixing bolt J 100 9 11 65 79 5 Copper washer ES HS 0 25 30 2 5 3 1 18 22 OZ SY SS Torque member Spring Cylinder body Second brake pad Dust seal Piston Piston seal x e Do not re use Rubber grease point F fluid point O Nem kg m in Ib NBR439 Pad Replacement WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials CAUTION e When cylinder body is open do not depress brake because piston will pop out e Becareful not to damage piston boot or get oil on rotor Always replace shims when replacing pads e If shims are rusted or show peeling of the rubber coat replace them with new shims e not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly In this case suspend cylinder body with wire so as not to stretch brake hose e Burnish the brake contact surfaces after refinishing or replacing rotors after replacing pads or if a soft pedal occurs at very low mileage Refer to Brake Burnishing Procedure CHECK AND ADJUSTMENT
65. oid valve Hydraulic circuit is shut off to hold the wheel cylinder Pressure hold ON Closed OFF Closed brake pressure Wheel cylinder brake fluid is sent to reservoir via the ABS operation ON Closed ON Open outlet solenoid valve Then it is pushed up to the mas decrease ter cylinder by pump Pressure OFF Open OFF Closed Master cylinder brake fluid pressure is transmitted to increase wheel cylinder BR 52 ANTI LOCK BRAKE SYSTEM Removal and Installation CAUTION Be careful not to damage sensor edge and sensor rotor teeth When removing the front or rear wheel hub assembly dis connect the ABS wheel sensor from the assembly and move it away Failure to do so may result in damage to the sensor or wiring making it inoperative FRONT WHEEL SENSOR 18 24 1 8 2 4 13 18 kg m ft lb NBR176 kg m ft lb NBR296 BR 53 ANTI LOCK BRAKE SYSTEM Front sensor rotor Drive shaft Rear sensor rotor Suitable drift SBR873CA Td NBR196 Rear sensor rotor Press Sensor fa ABS control unit 4 harness connector e ABS control unit TR Removal and Installation Cont d SENSOR ROTOR Removal 1 Remove the drive shaft and rear wheel hub Refer to FA RA section Drive Shaft FRONT AXLE and Wheel Hub
66. onnect ABS actuator and electric unit connector Does the warning lamp activate See below CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the con nection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest Inspection end REPLACE Replace ABS actuator and electric unit CHECK HARNESS FOR SHORT 1 Disconnect ABS actuator and elec tric unit connector 2 Check voltage between ABS actua tor and electric unit connector body side terminal 21 22 and ground Battery voltage should not exist Repair harness or con nector between fuse and ABS actuator and electric unit connector terminal CHECK COMBINATION METER Check combination meter Refer to WARNING LAMPS in EL section BR 89 TROUBLE DIAGNOSES FOR SYMPTOMS ABS warning 1 21 CVT models 22 M T models NBR418 Diagnostic Procedure 12 Warning lamp stays on when ignition switch is turned ON CHECK WARNING LAMP 1 Disconnect ABS actuator and electric unit connector 2 Connect suitable wire between ABS actuator and electric unit connector body side terminal 69 and ground Warning lamp should not activate OK NG Repair combination meter Check the following e Harness connector E78 e Harness for open
67. ore to complete the bur nishing procedure Bleeding Brake System CAUTION Carefully monitor brake fluid level at master cylinder during bleeding operation If master cylinder is suspected to have air inside bleed air from master cylinder first Refer to Installation MASTER CYLINDER Fill reservoir with new brake fluid DOT 4 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 to the OFF position and disconnect ABS fuse or battery cable Bleed air in the following order RHD models Left rear brake Right front brake Right rear brake Left front brake LHD models Right rear brake Left front brake Left rear brake Right front brake Connect a transparent vinyl tube to air bleeder valve Fully depress brake pedal several times With brake pedal depressed open air bleeder valve to release air Close air bleeder valve Release brake pedal slowly Repeat steps 2 through 5 until clear brake fluid comes out of air bleeder valve Tighten air bleeder valve 7 9 N m 0 7 0 9 kg m 61 78 in Ib BR 8 BRAKE HYDRAULIC LINE Without anti lock brake system Rear drum brake Rear disc brake a Front disc brake Booster Dual proportioning valve Master cylinder nn With anti lock brake system Front disc brake Rear disc brak
68. ot Main pin bolt Inner shim 9 22 32 2 Pad 07 13 5 1 9 4 Dust seal Do not re use Cylinder body Piston 1 Piston seal Nem kg m ft lb e kg m in lb NBR438 Pad Replacement WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne particles or other materials CAUTION e When cylinder body is open do not depress brake pedal because piston will pop out e Be careful to damage piston boot or get oil on rotor Always replace shims when replacing pads e If shims are rusted or show peeling of the rubber coat replace them with new shims e Itis not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly In this case suspend cylinder body with wire so as not to stretch brake hose e Burnish the brake contact surfaces after refinishing or replacing rotors after replacing pads or if a soft pedal occurs at very low mileage Refer to Brake Burnishing Procedure CHECK AND ADJUSTMENT BR 23 FRONT DISC BRAKE Pad Replacement Cont d 1 Remove master cylinder reservoir cap 2 Remove lower pin bolt 3 Open cylinder body upward Then remove pad retainers and inner and outer shims Standard pad thickness 11 mm 0 43 in Pad wear limit 2 0 mm 0 079 in Carefully monitor brake fluid level because brake fluid will return to reservoir when pushing back piston
69. r relay 81 63 Solenoid valve relay BR 79 71 Control unit BR 84 Control unit power supply circuit Warning lamp bulb circuit Control unit or control unit connector BR 90 Solenoid valve relay stuck Power supply for solenoid valve relay coil ABS warning lamp stays on when ignition switch is turned on ABS warning lamp stays on during Control unit self diagnosis ABS warning lamp does not come e 7 Fuse warning lam lb or warning lamp circuit on when ignition switch is turned warning lamp or warning lamp Control unit on during self diagnosis contol unt Pedal vibration and noise 87 Long stopping distance BR 86 Unexpected pedal action 86 ABS does not work 87 ABS works frequently 85 Under voltage that is too low the control unit disable the ABS It does not set the ABS in fail safe condition Instead the ABS becomes a conventional brake system After the power supply has resumed the warning lamp goes off making it possible for the ABS to be re engaged BR 76 TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS 9 10 13 ABS actuator and electric unit Wheel sensor connectors sensor side Diagnostic Procedure 1 rotor Wheel sensor or Malfunction code No 21 22 25 26 31 32 35 36 or 18 for models with self diagnosis function Front RH Rear RH KA d dl NBR420 iss DISCONNECT
70. rcuit for rear right inlet solenoid valve is shorted An abnormally high output voltage is entered e Circuit for rear left inlet solenoid valve is shorted An abnormally high output voltage is entered e Circuit for front right outlet solenoid valve is open An abnormally low output voltage is entered FR LH OUT ABS SOL OPEN e Circuit for front left outlet solenoid valve is open An abnormally low output voltage is entered RR RH OUT ABS SOL OPEN e Circuit for rear right outlet solenoid valve is open An abnormally low output voltage is entered RR LH OUT ABS SOL OPEN FR RH OUT ABS SOL SHORT FR LH OUT ABS SOL SHORT Circuit for rear left outlet solenoid valve is open An abnormally low output voltage is entered e Circuit for front right outlet solenoid valve is shorted An abnormally high output voltage is entered e Circuit for front left outlet solenoid valve is shorted An abnormally high output voltage is entered RR RH OUT ABS SOL SHORT e Circuit for rear right outlet solenoid valve is shorted An abnormally high output voltage is entered RR LH OUT ABS SOL SHORT Circuit for rear left outlet solenoid valve is shorted An abnormally high output voltage is entered ABS ACTUATOR RELAY ABNORMAL e Actuator solenoid valve relay is ON even control unit sends off signal e Actuator solenoid valve relay is OFF even control unit sends on signal
71. self diagnosis function CHECK CONNECTOR No Inspection end 1 Disconnect ABS actuator and electric unit connector Check terminals for damage or loose connections Then reconnect con nector 2 Carry out self diagnosis again Does warning lamp activate again To solenoid valve relay ABS control unit YBR180 CHECK ABS CONTROL UNIT POWER NG SUPPLY CIRCUIT gt See below 1 Disconnect ABS actuator and electric unit connector 2 Check voltage between ABS actuator and electric unit connector terminal and ground Battery voltage should exist when ignition switch is turned ON 44 Q ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR 1 E78 OK YBR181 CHECK ABS CONTROL UNIT GROUND NG Repair harness and connec Refer to ABS ACTUATOR AND ELECTRIC tor UNIT GROUND in Ground Circuit Check BR 75 E CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the connection of ABS actuator and electric unit harness con nector Reconnect ABS actuator and electric unit harness connector Then retest 0 CHECK FUSE NG Replace fuse Check 10 fuse 19 For fuse layout refer to POWER SUPPLY ROUTING in EL sec tion OK CHECK ABS CONTROL UNIT POWER NG Check the following SUPPLY CIRCUIT e Harness connector Check continuity between fuse and ABS e Harness for open
72. t collector to minimize the hazard of airborne particles or other materials 1 Remove brake cable mounting bolt and lock spring 2 Release parking brake control lever then disconnect cable from the caliper 3 Remove torque member fixing bolts and connecting bolt It is not necessary to remove connecting bolt except for disassembly or replacement of caliper assembly In this case suspend caliper assembly with wire so as not to stretch brake hose Disassembly 1 Remove piston by turning it counterclockwise with long nose pliers or suitable tool 2 Pry off snap ring A from piston with suitable pliers and remove adjusting nut BR 35 REAR DISC BRAKE TYPE 1 SBR088B E SBR656 SBR767E Disassembly Cont d 3 Disassemble cylinder body a Pry off snap ring B with suitable pliers then remove spring cover spring and retaining washer b Remove key plate push rod O ring and strut c Remove piston seal Be careful not to damage cylinder body 4 Remove return spring toggle lever and cable guide Inspection Caliper CAUTION Use brake fluid to clean cylinder Never use mineral oil Cylinder Body e Check inside surface of cylinder for score rust wear dam age or presence of foreign materials If any of the above conditions are observed replace cylinder body e Minor damage from rust or foreign materials may be elimi nated by polishing surface with a fine emery paper
73. the brake pad Standard pad thickness 11 mm 0 43 in Pad wear limit 2 0 mm 0 079 in 14 Press the piston fully back with a suitable tool CAUTION Carefully monitor brake fluid level to avoid brake fluid from returning to the reservoir when pushing back the piston Installation 1 Install the brake pad with a three pronged retaining spring into the piston 2 Place the second brake pad into the guide groove of the torque member on the outer side of the brake disc 3 Place the cylinder body with the installed brake pad over the brake disc and the second brake pad 4 Tighten the guide pins with a 7 mm Allen key 5 Press back the protective caps into the guides sleeve BR 28 FRONT DISC BRAKE Installation Cont d Tidus member fg 6 Check the cylinder body retaining spring for damage if the spring is defective replace the spring 7 Click the cylinder body retaining spring in position and make sure that e two ends of spring click correctly into the locating holes of the cylinder body e spring is in the correct position against the lugs of the torque member Locating holes Torque member lug NBR292 Removal WARNING Clean brake pads with a vacuum dust collector to minimize the hazard of airborne materials CAUTION Suspend caliper assembly with wire to avoid stretching the brake hose Remove torque member fixing bolts and connecting bolt It is not necessary to remove con
74. tional speed of the rotor CONTROL UNIT The control unit determines the wheel rotating speed from the signal sent from the sensor a corresponding control signal is then output from the control unit in the form of a DC current to the actuator solenoid valve The ABS control unit also controls ON OFF operation of the valve relay and motor relay If any electrical malfunction should be detected in the system the con trol unit causes the warning lamp to light up In this condition the ABS will be deactivated by the control unit and the vehicle s brake system reverts to normal operation BR 51 ANTI LOCK BRAKE SYSTEM System Description Cont d Z ABS ACTUATOR AND ELECTRIC UNIT E m A d The ABS actuator and electric unit contains necs Ne e electric motor and pump control unit harness PE e Two relays connector s TES e Eight solenoid valves each inlet and outlet for LH front CM E3 RH front Yo SS Rear LH RH e ABS control unit E This component controls the hydraulic circuit and increases X NBR297 holds or decreases hydraulic pressure to all or individual wheels The ABS actuator and electric unit can not be disassembled and has to be serviced as an assembly ABS actuator operation Inlet solenoid Outlet solenoid valve valve OFF Closed Master cylinder brake fluid pressure is directly transmit Operation pee Open ted to wheel cylinder via the inlet solen
75. topping distance may be larger than vehicles without ABS when road condition is slippery Go to in Diagnostic Procedure 7 BR 86 TROUBLE DIAGNOSES FOR SYMPTOMS Diagnostic Procedure 9 ABS does not work CHECK WARNING LAMP ACTIVATE 18 ou Selt diagnosis Does the ABS warning lamp activate Refer to No Go to B in Diagnostic Procedure 7 Note ABS does not work when vehicle speed is under 10 km h 6 MPH Diagnostic Procedure 10 Pedal vibration and Brake pedal noise INSPECTION START is Carry 1 Apply brake Refer to 2 Start engine 3 Does the symptom appear only when engine is started No SAT797A No Does the symptom appear when elec Procedure 7 CHECK IF SYMPTOM APPEARS Go to E in Diagnostic trical equipment switches such as headlamp are operated Yes CHECK WHEEL SENSOR Repair wheel sensor Check wheel sensor shield ground For location of shield ground refer to wiring diagram and HARNESS LAYOUT in EL section OK CHECK HARNESS CONNECTOR Check ABS actuator and electric unit pin terminals for damage or the con nection of ABS actuator and electric unit harness connector Reconnect ABS actuator and electric unit harness connector Then retest Note ABS may operate and cause vibration under any of the following conditions BR 87 TROUBLE DIAGNOSES FOR SYMPTOMS warning
76. tuator and electric unit and fusible link If NG repair harness or OK REPLACE Replace ABS actuator and electric unit BR 79 connector TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Diagnostic Procedure 2 ABS actuator DISCONNECT ABS ACTUATOR AND ELECTRIC UNIT CONNECTOR YBR176 solenoid valve and solenoid Cont d valve relay REPLACE Inspection end Replace fusible link Does the fusible link blow out when ignition switch is turned ON CHECK SOLENOID VALVE RELAY POWER SUPPLY CIRCUIT 1 Disconnect battery cable and ABS actuator and electric unit connector 2 Check continuity between ABS actuator and electric unit connector body side terminal and ground Continuity should not exist REPLACE Replace ABS actuator and electric unit Check the following e Harness connector E78 e Harness for open or short between ABS actuator and electric unit and fusible link If NG repair harness or connector REPLACE Yes Replace fuse Does the fuse blow out when ignition switch is turned ON No END Inspection end BR 80 Check the following e Harness connector E78 e Harness for open or short between ABS actuator and electric unit and fuse If NG repair harness or connector TROUBLE DIAGNOSES FOR SELF DIAGNOSTIC ITEMS Fuse 19
77. tube SBR225B e Install check valve paying attention to its direction Be Intake manifold Brake booster side SBR498A CAUTION Caution label ENG _____ NRE Inspection HOSES AND CONNECTORS Check vacuum lines connections and check valve for air tightness improper attachment chafing and deterioration CHECK VALVE pu Check vacuum with a vacuum pump lt Connect to Booster side Engine side Vacuum should exist booster side Connect to S Vacuum should not exist engine side SBR943A BR 21 VACUUM HOSE Inspection Cont d Engine side Arrow indicates engine side SBR844B Rec AWG VACUUM PUMP CN Vacuum gauge T 1 Install vacuum gauge s 2 Run engine at 1 000 rpm or more 3 Check vacuum Specified vacuum 86 6 kPa 866 mbar 650 mmHg 25 59 inHg or more BR 22 FRONT DISC BRAKE SEC 440 8 Rubber grease point Brake fluid point B PBC Poly Butyl Cyprysil grease or silicon based grease point Main pin 9 to sliding portion Pin boot Torque member Torque member fixing bolt 0 108 9 11 65 79 Main pin 8 to sliding portion 2 2 3 3 16 24 Connecting bolt 9 17 20 1 7 2 0 12 15 yas Copper washer 6 PS Outer shim Bleed F 7 Pad retainer Piston shim Pad retainer Pin bo
78. witch C C4 Clearance between pedal stopper rubber and threaded end of brake lamp switch or redun dant brake switch 0 75 2 0 mm 0 03 0 08 in A Pedal free play 1 3 mm 0 039 0 118 A Floor carpet Floor carpet Dash insulator Dash Insulator Floor panel Melt sheet SBR110B BR 13 BRAKE PEDAL AND BRACKET Adjustment Cont d 1 Loosen lock nut and adjust pedal free height by turning brake Stays inside booster input rod Then tighten lock nut 2 Check pedal free play Make sure that brake lamps go off when pedal is released 3 Check brake pedal s depressed height while engine is run ning If depressed height is below specified value check brake system for leaks accumulation of air or any damage to com Lock nut Clevis ponents master cylinder wheel cylinder etc then make necessary repairs Input rod SBR229E BR 14 MASTER CYLINDER Removal sec 460 14 17 Nm 1 5 1 7 kg m 11 12 446 NBR436 1 Reservoir cap 5 Cylinder body 8 Secondary piston assembly 2 Oil filter 6 Elastic pin 9 Primary piston assembly 3 Reservoir tank 7 Piston stopper pin 10 Circlip 4 Seal 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 1 Disconnect fluid level connector 2 Connect a vinyl tube to air bleeder valv

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