2005 NISSAN NAVARA ABS

BR-18
BRAKE MASTER CYLINDER
Disassembly and Assembly
EFS005SS
DISASSEMBLY
CAUTION:
lMaster cylinder assembly cannot be disassembled.
lRemove reservoir tank only when absolutely necessary.
Pull reservoir tank off master cylinder sub-assembly, then remove grommets from master cylinder sub-assem-
bly body.
ASSEMBLY
CAUTION:
lDo not use mineral oils such as kerosene, gasoline during the cleaning and assembly process.
lDo not drop parts. If a part is dropped, do not use it.
1. Apply brake fluid to the grommet and attach to the cylinder body.
2. Install reservoir tank onto the cylinder body.

BR-20
BRAKE BOOSTER
Removal and Installation
EFS005SU
COMPONENTS
REMOVAL
CAUTION:
lBe careful not to deform or bend brake tube while removing and installing the brake booster.
lReplace clevis pin if it is damaged.
lBe careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined dur-
ing installation, the dash panel may damage the threads.
1. Remove ABS actuator and electric unit (control unit). Refer toBRC-40, "
Removal and Installation".
2. Remove brake tube from brake master cylinder.
3. Remove brake master cylinder. Refer toBR-17, "
Removal and Installation".
4. Remove vacuum hose from brake booster. Refer toBR-23, "
Removal and Installation".
5. Remove brake pedal attachment snap pin and clevis pin from inside vehicle.
6. Remove nuts on brake booster and brake pedal assembly.
7. Remove brake booster assembly from dash panel.
INSPECTION AFTER REMOVAL
Output Rod Length Inspection
1. Using a handy vacuum pump, apply a vacuum of –66.7 kPa (–
500 mmHg, –19.69 inHg) to the brake booster.
2. Check output rod length.
1. Reservoir tank 2. Master cylinder 3. Gasket
4. Brake pedal 5. Lock nut 6. Brake booster
7. Spacer
Refer to GI section for symbol marks in the figure.
SFIA3194E
Standard dimension at a vacuum of –66.7 kPa
(–500 mmHg, –19.69 inHg)
: –15.6 mm - 15.9 mm (–0.614 - 0.626 in)
SBR208E

BRAKE BOOSTER
BR-21
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INSTALLATION
1. Loosen the lock nut to adjust the input rod length so that the
length B (in the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten the lock nut to install the
booster assembly to the vehicle. At this time, securely install a
gasket and spacer block between the booster assembly and the
dash panel.
3. Connect brake pedal with the clevis of the input rod.
4. Install brake booster mounting nuts and tighten them to the
specified torque.Refer toBR-20, "
COMPONENTS".
5. Install brake tube from brake master cylinder to ABS actuator and electric unit (control unit). Refer toBR-
12, "Hydraulic Circuit".
6. Connect vacuum hose to brake booster.
7. Install master cylinder to brake booster assembly. Refer toBR-17, "
Removal and Installation".
8. Adjust the height and play of brake pedal.Refer toBR-6, "
Inspection and Adjustment".
9. Tighten lock nut of input rod to the specified torque. Refer toBR-7, "
ADJUSTMENT".
10. Refill new brake fluid and bleed air. Refer toBR-11, "
Bleeding Brake System". Length“B” :145-152mm(5.71-5.98in)
SGIA0060E

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTIONBRC
A
B
BRC
BRAKE CONTROL SYSTEM
ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 3
PREPARATION ........................................................... 4
Special Service Tools (SST) ..................................... 4
SYSTEM DESCRIPTION ............................................ 5
System Diagram ....................................................... 5
Functions .................................................................. 5
Operation That Is Not “System Error” ...................... 5
Fail-Safe Function .................................................... 5
ABS, EBD SYSTEM .............................................. 5
Hydraulic Circuit Diagram ........................................ 6
CAN COMMUNICATION ............................................ 7
System Description .................................................. 7
TROUBLE DIAGNOSIS .............................................. 8
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ....................................................... 8
INTRODUCTION ................................................... 8
DIAGNOSIS FLOWCHART .................................. 9
ASKING COMPLAINTS ...................................... 10
EXAMPLE OF DIAGNOSIS SHEET ................... 10
Component Parts Location ...................................... 11
Schematic — ABS — ............................................. 12
Wiring Diagram — ABS — ..................................... 13
CONSULT- II Functions .......................................... 17
CONSULT-II MAIN FUNCTION ........................... 17
CONSULT-II BASIC OPERATION PROCEDURE
... 17
Self-Diagnosis ........................................................ 18
OPERATION PROCEDURE ............................... 18
ERASE MEMORY ............................................... 18
DISPLAY ITEM LIST ........................................... 18
Data Monitor ........................................................... 20
OPERATION PROCEDURE ............................... 20
DISPLAY ITEM LIST ........................................... 20Active Test .............................................................. 21
OPERATION PROCEDURE ................................ 21
SOLENOID VALVE .............................................. 22
ABS MOTOR ....................................................... 22
For Fast and Accurate Diagnosis ........................... 23
PRECAUTIONS FOR DIAGNOSIS ..................... 23
Basic Inspection ..................................................... 23
BASIC INSPECTION 1 BRAKE FLUID LEVEL,
LEAKS, AND BRAKE PADS ................................ 23
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 23
BASIC INSPECTION 3 ABS WARNING LAMP
AND BRAKE WARNING LAMP INSPECTION .... 24
Inspection 1 Wheel Sensor System ........................ 24
Inspection 2 ABS Actuator and Electric Unit (Control
Unit) ........................................................................ 26
Inspection 3 ABS Actuator Relay or ABS Motor
Relay Circuit ........................................................... 26
Inspection 4 CAN Communication Circuit .............. 28
Inspection 5 ABS Actuator and Electric Unit (Control
Unit) Power Supply and Ground Circuit .................. 28
Inspection 6 Brake Fluid Level Switch Circuit ......... 30
Inspection 7 Parking Brake Switch Circuit .............. 32
Inspection 8 Warning lamp system ......................... 33
Symptom 1: Excessive ABS Function Operation
Frequency ............................................................... 33
Symptom 2: Unexpected Pedal Reaction ............... 34
Symptom 3: The Stopping Distance Is Long .......... 34
Symptom 4: ABS Function Does Not Operate ....... 35
Symptom 5: Pedal Vibration or ABS Operation
Sound Occurs ......................................................... 35
Symptom 6: ABS Warning Lamp Indication Is Not
Normal .................................................................... 35
WHEEL SENSORS ................................................... 37
Removal and Installation ........................................ 37
REMOVAL ........................................................... 38
INSTALLATION ................................................... 38

PRECAUTIONS
BRC-3
[ABS]
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BRC
[ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS006DM
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
lTo 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 must be per-
formed by an authorized NISSAN/INFINITI dealer.
lImproper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
lDo not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake SystemEFS005TG
lRecommended fluid is brake fluid “DOT 3” or “DOT 4”.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.If brake fluid is splashed, wipe it off and flush area
with water immediately.
lNever use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system.
lUse flare nut wrench when removing flare nuts, and use a flare
nut torque wrench when tighten flare nuts.
lBrake system is an important safety part.If a brake fluid leak is
detected, always disassemble the affected part.If a malfunction
is detected, replace part with new one.
lBefore working, turn ignition switch OFF and disconnect con-
nector of ABS actuator and electric unit (control unit) or the bat-
tery cables.
lWhen installing brake tube and hose, be sure to torque.
WARNING:
Clean brake pads and shoes with a waster cloth, then wipe with
a dust collector.
Precautions for Brake ControlEFS005TH
lJust after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may
be heard from engine room. This is a normal status of operation check.
lStopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
lWhen an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnostic servicing. Besides electrical system inspection, check brake booster operation, brake fluid
level, and fluid leaks.
lIf tyre size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
lIf there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ABS function
may have a malfunction or error.
lIf aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.
SBR820BA

BRC-4
[ABS]
PREPARATION
PREPARATION
PFP:00002
Special Service Tools (SST)EFS005TI
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
a:10 mm (0.39 in)Installing brake tube and hose
ST30720000
Drift
a: 77 mm (0.03 in) dia.
b: 55 mm (2.17 in) dia.
Installation rear sensor rotor ST27863000
Drift
a: 75 mm (2.95 in) dia.
b: 62 mm (2.44 in) dia.
KV40104710
Drift
a: 76 mm (2.99 in) dia.
b: 68.5 mm (2.697 in) dia.
NT406
ZZA0701D
ZZA0832D
ZZA0832D

SYSTEM DESCRIPTION
BRC-5
[ABS]
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SYSTEM DESCRIPTIONPFP:00000
System DiagramEFS005TJ
FunctionsEFS005TK
ABS
lThe Anti-Lock Brake System is a function that detects wheel revolution while braking, and it improves
handling stability during sudden braking by electrically preventing 4 wheels lock. Maneuverability is also
improved for avoiding obstacles.
lElectrical system diagnosis by CONSULT-II is available.
EBD
lElectronic Brake Distributor is a function that detects subtle slippages between the front and rear tyre dur-
ing braking, and it improves handling stability by electrically controlling the brake fluid pressure which
results in reduced rear tyre slippage.
lElectrical system diagnosis by CONSULT-II is available.
Operation That Is Not “System Error”EFS005TL
ABS
lWhen starting engine or just after starting vehicle, brake pedal may vibrate or the motor operating noise
may be heard from engine room. This is a normal states of the operation check.
lDuring ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal.
lStopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
Fail-Safe FunctionEFS005TM
ABS, EBD SYSTEM
In case of electrical malfunction with ABS, ABS warning lamp will turn on. In case of electrical incidents with
EBD, brake warning lamp and ABS warning lamp will turn on. Simultaneously, ABS become one of following
conditions of Fail-Safe function.
1. For ABS malfunction, only EBD is activated and condition of vehicle is same condition of vehicles without
ABS system.
NOTE:
ABS self-diagnosis sound may be heard.That is a normal condition because a self-diagnosis for “Ignition
switch ON” and “The first starting” are being performed.
2. For EBD malfunction, EBD and ABS become inoperative, and condition of vehicle is same as condition of
vehicles without ABS, EBD system.
SFIA3001E

BRC-6
[ABS]
SYSTEM DESCRIPTION
Hydraulic Circuit Diagram
EFS005TN
SFIA3205E