2005 NISSAN NAVARA brake sensor

BR-24
FRONT DISC BRAKE
FRONT DISC BRAKE
PFP:41000
On-Board InspectionEFS005SY
PAD WEAR INSPECTION
lCheck pad thickness from a inspection hole on cylinder body.
Check using a scale if necessary.
ComponentsEFS005SZ
Standard thickness : 11.0 mm (0.43 in)
Repair limit thickness : 2.0 mm (0.08 in)
MAA0439D
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Sliding pin 12. Sliding pin boot
13. Bushing 14. Torque member mounting bolt 15. Torque member
16. Inner shim 17. Inner pad 18. Pad wear sensor (RH side)
19. Pad retainer 20. Outer pad 21. Outer shim
1: Rubber grease 2: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease3: Polyglycol ether based lubricant
SFIA3168E

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
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

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

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.

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-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]

TROUBLE DIAGNOSIS
BRC-33
[ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC
Inspection 8 Warning lamp systemEFS005U7
INSPECTION PROCEDURE
1.CHECK SELF-DIAGNOSTIC RESULTS
Perform self-diagnosis of ABS actuator and electric unit (control unit). Refer toBRC-18, "
Self-Diagnosis".
OK or NG
OK >> GO TO 2.
NG >> Check items displayed by self-diagnosis. Refer toBRC-18, "
Display Item List".
2.CHECK COMBINATION METER
Check if the indication and operation of combination meter are normal. Refer toDI-13, "
Self-Diagnosis Mode
of Combination Meter".
OK or NG
OK >> INSPECTION END
NG >> Repair or replace combination meter. Refer toDI-27, "
Removal and Installation of Combination
Meter".
Symptom 1: Excessive ABS Function Operation FrequencyEFS005U8
1.CHECK START
Check longitudinal brake force distribution using a brake tester. Refer toBR-35, "
SERVICE DATA AND SPEC-
IFICATIONS (SDS)".
OK or NG
OK >> GO TO 2.
NG >> Check the following system. If any malfunction is found, repair or replace malfunctioning parts.
lBrake booster. Refer toBR-19, "BRAKE BOOSTER".
lHydraulic line. Refer toBR-12, "BRAKE TUBE AND HOSE".
lFront brake caliper. Refer toBR-24, "FRONT DISC BRAKE".
lRear wheel cylinder. Refer toBR-30, "REAR DRUM BRAKE".
2.CHECK FRONT AND REAR AXLE
Make sure that there is no excessive play in the front and rear axles. Refer to Front:FAX-5, "
WHEEL BEAR-
ING INSPECTION",Rear:RAX-6, "Rear Axle Bearing".
OK or NG
OK >> GO TO 3.
NG >> Repair.
3.CHECK WHEEL SENSOR AND SENSOR ROTOR
Check wheel sensor and sensor rotor for the following.
lWheel sensor installation for damage
lWheel sensor rotor installation for damage
lWheel sensor connector connection
lWheel sensor harness inspection
OK or NG
OK >> GO TO 4.
NG >>
lReplace wheel sensor or sensor rotor.
lRepair harness.

BRC-34
[ABS]
TROUBLE DIAGNOSIS
4.CHECK ABS WARNING LAMP DISPLAY
Make sure that the ABS warning lamp is turned off after the ignition switch is turned ON or when driving.
OK or NG
OK >> Normal
NG >> Perform self-diagnosis. Refer toBRC-18, "
Self-Diagnosis".
Symptom 2: Unexpected Pedal ReactionEFS005U9
1.CHECK BRAKE PEDAL STROKE
Check brake pedal stroke. Refer toBR-6, "
Inspection and Adjustment".
Is the stroke too big?
YES >>lBleed air from brake piping. Refer toBR-11, "Bleeding Brake System".
lCheck brake pedal, brake booster, and master cylinder for mount play, looseness, brake sys-
tem fluid leakage, etc. Repair if necessary. Refer to Brake pedal:BR-8, "
COMPONENTS",
brake booster and master cylinder:BR-20, "
COMPONENTS".
NO >> GO TO 2.
2.CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS. Check if braking force is
normal in this condition. Connect connector after inspection.
OK or NG
OK >> GO TO procedure 3 “CHECK WHEEL SENSOR AND SENSOR ROTOR” of symptom 1. Refer to
BRC-33, "
Symptom 1: Excessive ABS Function Operation Frequency".
NG >> Check the following system. If any malfunction is found, repair or replace malfunctioning parts.
lBrake booster. Refer toBR-19, "BRAKE BOOSTER".
lHydraulic line. Refer toBR-12, "BRAKE TUBE AND HOSE".
lFront brake caliper. Refer toBR-24, "FRONT DISC BRAKE".
lRear wheel cylinder. Refer toBR-30, "REAR DRUM BRAKE".
Symptom 3: The Stopping Distance Is LongEFS005UA
CAUTION:
The stopping distance on slippery road surfaces might be longer with the ABS operating than when
the ABS is not operating.
1.CHECK FUNCTION
Turn ignition switch OFF. Disconnect ABS actuator and electric unit (control unit) connector to deactivate ABS.
In this condition, check stopping distance. After inspection, connect connector.
OK or NG
OK >> GO TO procedure 3 “CHECK WHEEL SENSOR AND SENSOR ROTOR” of symptom 1. Refer to
BRC-33, "
Symptom 1: Excessive ABS Function Operation Frequency".
NG >>
lBleed air from the brake piping. Refer toBR-11, "Bleeding Brake System".
lCheck the following system. If any malfunction is found, repair or replace malfunctioning parts.
–Brake booster. Refer toBR-19, "BRAKE BOOSTER".
–Hydraulic line. Refer toBR-12, "BRAKE TUBE AND HOSE".
–Front brake caliper. Refer toBR-24, "FRONT DISC BRAKE".
–Rear wheel cylinder. Refer toBR-30, "REAR DRUM BRAKE".