2005 NISSAN NAVARA wheel

BR-34
REAR DRUM BRAKE
Removal and Installation of Wheel Cylinder
EFS006AH
REMOVAL
1. Drain brake fluid. Refer toBR-10, "Drain and Refill".
2. Remove rear brake shoe assembly.
3. Remove brake tube from the wheel cylinder.
4. Remove bolts on the wheel cylinder, and then remove wheel cylinder from the back plate.
INSTALLATION
lInstallation is the reverse order of removal. Tighten bolts to the specified torque. Refer toBR-30, "Compo-
nents".
lRefill with new brake fluid and bleed air. Refer toBR-11, "Bleeding Brake System".
Disassembly and Assembly of Wheel CylinderEFS006AI
DISASSEMBLY
1. Remove boots at the right and left of the wheel cylinder, and pull
out the pistons from cylinder.
2. Remove piston from piston cup.
INSPECTION AFTER DISASSEMBLY
Check the pistons, piston cups, and inner wall of the cylinder for wear, corrosion, and damage. If malfunction
is detected, replace it.
ASSEMBLY
CAUTION:
lDo not use Nissan rubber grease (KRE0000010, KRE000001001) during assembly.
lWhen inserting the piston, be careful not to scratch the cylinder.
1. Apply brake fluid to the piston sliding surface on the wheel cylinder.
2. Apply polyglycol ether based lubricant to the piston cups and
piston boots and assemble as shown in the figure.
SFIA3077E
SFIA3078E

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

SYSTEM DESCRIPTION
BRC-5
[ABS]
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BRC
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-18
[ABS]
TROUBLE DIAGNOSIS
Self-Diagnosis
EFS005TU
OPERATION PROCEDURE
1. Turn ignition switch OFF.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector.
3. Turn ignition switch ON.
4. Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
5. After stopping vehicle, with engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG
RESULTS” in order on CONSULT-II screen.
CAUTION:
If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turn on the
ignition switch, “ABS” might not be displayed in the “SELECT SYSTEM” screen. In this case,
repeat the operation from step 1.
6. The self-diagnostic results are displayed. (Touch “PRINT” to print out self-diagnostic results, If necessary.)
lCheck ABS warning lamp if “NO FAILURE” is displayed.
7. Perform the appropriate inspection from display item list, and repair or replace the malfunctioning compo-
nent. Refer toBRC-18, "
Display Item List".
8. Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute.
CAUTION:
When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning
lamp and brake warning lamp will not turn off even when the system is normal unless the vehicle
is driving at 30 km/h (19MPH) or more for approximately 1 minute.
ERASE MEMORY
1. Turn ignition switch OFF.
2. Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE
MEMORY” in order on CONSULT-II screen to erase the error memory.
If “ABS” is not indicated, go toGI-50, "
CONSULT-II Data Link Connector (DLC) Circuit".
CAUTION:
If the error memory is not erased, re-perform the operation from step 4.
3. Perform self-diagnosis again, and make sure that diagnostic memory is erased.
4. Drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make
sure that the ABS warning lamp turn off.
DISPLAY ITEM LIST
Self-diagnostic item Malfunction detecting condition Check system
RR RH SENSOR-1 Circuit of rear RH wheel sensor is open.
BRC-24, "
Inspection 1
Wheel Sensor System"
(Note 1) RR LH SENSOR-1 Circuit of rear LH wheel sensor is open.
FR RH SENSOR-1 Circuit of front RH wheel sensor is open.
FR LH SENSOR-1 Circuit of front LH wheel sensor is open.
RR RH SENSOR-2When the circuit in the rear RH wheel sensor is short-circuited. Or
when the sensor power voltage is outside the standard. When the
distance between the wheel sensor and sensor rotor is too large
and the sensor pulse cannot be recognized by the control unit.
RR LH SENSOR-2When the circuit in the rear LH wheel sensor is short-circuited. Or
when the sensor power voltage is outside the standard. When the
distance between the wheel sensor and sensor rotor is too large
and the sensor pulse cannot be recognized by the control unit.
FR RH SENSOR-2When the circuit in the front RH wheel sensor is short-circuited. Or
when the sensor power voltage is outside the standard. When the
distance between the wheel sensor and sensor rotor is too large
and the sensor pulse cannot be recognized by the control unit.
FR LH SENSOR-2When the circuit in the front LH wheel sensor is short-circuited. Or
when the sensor power voltage is outside the standard. When the
distance between the wheel sensor and sensor rotor is too large
and the sensor pulse cannot be recognized by the control unit.

TROUBLE DIAGNOSIS
BRC-19
[ABS]
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BRC
Note 1: After completing repairs of shorted sensor circuit, when ignition switch is turned ON, ABS warning lamp turns on. Make sure that
ABS warning lamp turns off while driving vehicle at 30 km/h (19 MPH) or more for approximately 1 minute according to self-diagnosis
procedure. In addition, if wheel sensor 2 is displayed for wheels, check wheel sensor circuit and also check control unit power voltage.
Note 2: When errors are detected in several systems, including CAN communication system [U1000], troubleshoot CAN communication
circuit. Refer toBRC-28, "
Inspection 4 CAN Communication Circuit". BATTERY VOLTAGE
[MALFUNCTION]ABS actuator and electric unit (control unit) power voltage is too low.BRC-28, "
Inspection 5
ABS Actuator and Elec-
tric Unit (Control Unit)
Power Supply and
Ground Circuit"
CONTROLLER FAILURE Internal malfunction of ABS actuator and electric unit (control unit)BRC-26, "
Inspection 2
ABS Actuator and Elec-
tric Unit (Control Unit)"
PUMP MOTORDuring actuator motor operation with ON, when actuator motor turns
OFF or when control line for actuator motor relay is open.BRC-26, "
Inspection 3
ABS Actuator Relay or
ABS Motor Relay Cir-
cuit"During actuator motor operation with OFF, when actuator motor
turns ON or when control line for relay is shorted to ground.
ABS SENSOR
[MALFUNCTION SIGNAL]Wheel sensor input is malfunction.BRC-24, "
Inspection 1
Wheel Sensor System"
(Note 1)
FR LH IN ABS SOLWhen the control unit detects an error in the front LH inlet solenoid
circuit.
BRC-26, "
Inspection 3
ABS Actuator Relay or
ABS Motor Relay Cir-
cuit"
FR LH OUT ABS SOLWhen the control unit detects an error in the front LH outlet solenoid
circuit.
FR RH IN ABS SOLWhen the control unit detects an error in the front RH inlet solenoid
circuit.
FR RH OUT ABS SOLWhen the control unit detects an error in the front RH outlet solenoid
circuit.
RR LH IN ABS SOLWhen the control unit detects an error in the rear LH inlet solenoid
circuit.
RR LH OUT ABS SOLWhen the control unit detects an error in the rear LH outlet solenoid
circuit.
RR RH IN ABS SOLWhen the control unit detects an error in the rear RH inlet solenoid
circuit.
RR RH OUT ABS SOLWhen the control unit detects an error in the rear RH outlet solenoid
circuit.
ACTUATOR RLY When the control unit detects an error in the actuator relay circuit.
CAN COMM CIRCUIT
[U1000]When there is an error in the CAN communications.BRC-28, "
Inspection 4
CAN Communication
Circuit"(Note 2) Self-diagnostic item Malfunction detecting condition Check system

BRC-20
[ABS]
TROUBLE DIAGNOSIS
Data Monitor
EFS005TV
OPERATION PROCEDURE
1. Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on CONSULT-II screen.
CAUTION:
When “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on
ignition switch, “ABS” might not be displayed in “SELECT SYSTEM” screen. In this case, repeat
the operation from step 1.
2. At the monitor item selection screen, touch one of the item “ECU INPUT SIGNALS”, “MAIN SIGNALS” or
“SELECTION FROM MENU”.
3. Touch “START” to proceed to the data monitor screen.
DISPLAY ITEM LIST
CAUTION:
The display shows the control unit calculation data, so a normal value might be displayed even in the
event the output circuit (harness) is open or short-circuited.
E:ECU INPUT SIGNALS M:MAIN SIGNALS S:SELECTION FROM MENU
SELECT
MONITOR
ITEMMonitor item Display contentData monitor
ConditionReference value in
normal operation
E, M, SFR LH SENSOR
FR RH SENSOR
RR LH SENSOR
RR RH SENSORWheel speed0 [km/h] Vehicle stopped
Nearly matches the speed-
ometer display (±10% or
less)Vehicle running
(Note 1)
E, M, S STOP LAMP SW Brake pedal operationBrake pedal depressed ON
Brake pedal not depressed OFF
E, M, S BATTERY VOLTBattery voltage supplied to the ABS
actuator and electric unit (control
unit)Ignitionswitch ON 10–16V
M, SFR 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 SOLOperation status of all solenoid
valveActuator (solenoid valve) is
active (“Active Test ”with
CONSULT-II) or actuator
relay is inactive (in fail-safe
mode).ON
When the actuator (sole-
noid valve) is not active
and actuator relay is active
(ignition switch ON).OFF
M, S MOTOR RELAYMotor and motor relay operation
statusWhen the motor relay and
motor are operatingON
When the motor relay and
motor are not operatingOFF
M, S ACTUATOR RLY Actuator relay operation statusWhen the actuator relay is
operatingON
When the actuator relay is
not operatingOFF
M, S ABS WARN LAMPABS warning lamp status
(Note 2)When ABS warning lamp is
ON.ON
When ABS warning lamp is
OFF.OFF
S EBD WARN LAMP Brake warning lamp status (Note 2)Brake warning lamp ON ON
Brake warning lamp OFF OFF
S EBD SIGNAL EBD operationEBD active ON
EBD not active OFF

BRC-22
[ABS]
TROUBLE DIAGNOSIS
SOLENOID VALVE
NOTE:
The example shown is for front right wheel. The procedure for the other wheels is the same as given below.
1. For ABS solenoid valve, touch “UP”, “KEEP”, and “DOWN” on
the display screen. Make sure solenoid valve operates as
shown in solenoid valve operation chart.
Solenoid Valve Operation Chart
*: ON for 1 to 2 seconds after the touch, and then OFF
ABS MOTOR
Touch “ON” and “OFF” on the screen. Make sure ABS motor relay
and actuator relay operates as shown in table below.
SFIA0678E
OperationABS solenoid valve
UP KEEP DOWN
FR RH IN SOL OFF ON ON
FR RH OUT SOL OFF OFF ON*
Operation ON OFF
MOTOR RELAY ON OFF
ACTUATOR RLY ON ON
SFIA0593E

BRC-24
[ABS]
TROUBLE DIAGNOSIS
BASIC INSPECTION 3 ABS WARNING LAMP AND BRAKE WARNING LAMP INSPECTION
ON and OFF Timing for ABS Warning Lamp, Brake Warning Lamp
´:ON –:OFF
Note 1:Brake warning lamp will turn on in case of operating parking brake (switch turned on) or of a actuating brake fluid level switch
(brake fluid is insufficient).
Note 2:After starting engine, turn OFF.
Check the following items when unsuitable for an above condition.
lABS warning lamp: Refer toBRC-28, "Inspection 4 CAN Communication Circuit".
lBrake waning lamp: Refer toBRC-28, "Inspection 4 CAN Communication Circuit",BRC-30, "Inspection 6
Brake Fluid Level Switch Circuit",BRC-32, "Inspection 7 Parking Brake Switch Circuit".
If malfunction is not found, refer toBRC-33, "
Inspection 8 Warning lamp system".
Inspection 1 Wheel Sensor SystemEFS005TZ
Check each part according to CONSULT-II self-diagnostic results, and then identify the parts to be replaced.
CAUTION:
Check each part between wheel sensor terminals.
INSPECTION PROCEDURE
1.CHECK SELF-DIAGNOSTIC RESULTS
Check self-diagnostic results.
Is above displayed in self-diagnosis display items?
YES >> GO TO 2.
NO >> INSPECTION END
2.CHECK TYRE
Check air pressure, wear and size.
Are air pressure, wear and size within standard values?
YES >> GO TO 3.
NO >> Adjust air pressure, or replace tyre.
Condition ABS warning lampBrake warning lamp
[Note 1]Remarks
Ignition SW OFF – — —
Approx. 2 seconds after ignition
switch is turned ON´´[Note 2] —
Approx. 2 seconds later after ignition
switch ON–´[Note 2]Go out 2 seconds after ignition
switch is turned ON.
ABS error´—There is an ABS actuator and
electric unit (control unit) error.
(Power, ground or system mal-
function)
EBD error´´—
Self-diagnostic results
FR RH SENSOR-1,-2
FR LH SENSOR- 1,-2
RR RH SENSOR-1,-2
RR LH SENSOR-1,- 2
ABS SENSOR [MALFUNCTION SIGNAL]