INTELLIGENT KEY SYSTEM
BL-119
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Revision: 2007 April2007 M35/M45
Check Trunk Lid Opener Cancel SwitchNIS001Y0
1. CHECK TRUNK LID OPENER CANCEL SWITCH
With CONSULT-II
Check trunk lid opener cancel sensor (“TR CANCEL SW”) in “DATA MONITOR” mode.
Without CONSULT-II
1. Turn ignition switch OFF.
2. Check voltage between Intelligent Key unit connector and ground.
OK or NG
OK >> Trunk lid opener cancel switch is OK.
NG >> GO TO 2.
2. CHECK TRUNK LID OPENER CANCEL SWITCH CIRCUIT
1. Disconnect Intelligent Key unit and trunk lid opener cancel switch connector.
2. Check continuity between Intelligent Key unit connector and trunk lid opener cancel switch connector.
3. Check continuity between Intelligent Key unit connector and
ground.
OK or NG
OK >> GO TO 3.
NG >> Repair or replace harness between Intelligent Key unit and trunk lid opener cancel switch.
Monitor item Condition
TR CANCEL SWTrunk lid opener cancel switch ON: ON
Trunk lid opener cancel switch OFF: OFF
PIIB6400E
Terminals
Trunk lid
opener cancel
switch condi-
tionVoltage (V)
(Approx.) (+)
(–)
Intelligent Key
unit connectorTerminal
M32 23 GroundON 0
OFF (Cancel) 5
PIIB6390E
AB
Continuity
Intelligent Key
unit connectorTe r m i n a l Trunk lid opener
cancel switch
connectorTerminal
M32 23 M99 1 Yes
A
GroundContinuity
Intelligent Key unit
connectorTerminal
M32 23 No
PIIB6393E
INTELLIGENT KEY SYSTEM/ENGINE START FUNCTION
BL-151
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Revision: 2007 April2007 M35/M45
CAUTION:
When CAN COMM CIRCUIT [U1000] and CONTROL UNIT (CAN) [U1010] are displayed, give priority to performing trouble diag-
nosis.
DATA MONITOR
IGN POWER CIRCUIT
[B2553]It continues for 2 seconds or more that ON power sup-
ply input to Intelligent Key unit is excessively low when
the power supply position is in ON positionCheck Intelligent Key
unit ON power supply
inputBL-161
ACC POWER CIRCUIT
[B2554]It continues for 2 seconds or more that ACC power
supply input to Intelligent Key unit is excessively low
when the power supply position is in ACC or ON posi-
tionCheck Intelligent Key
unit ACC power supply
inputBL-162
STOP LAMP CIRCUIT
[B2555]5V or less is detected at both the stop lamp switch sig-
nal input circuit that is input to Intelligent Key unit and
the monitor input before stop lamp switchCheck stop lamp switchBL-165
ENG START SW
[B2556]Condition that push-button ignition switch is pushed is
detected continuously for 100 seconds or moreCheck push-button igni-
tion switchBL-166
VEHICLE SPEED
[B2557]Some differences occur on one or more vehicle speed
inputs of Intelligent Key unitCheck vehicle speed sig-
nalBL-167
SHIFT POSITION
[B2558]
There is a difference between the shift position input
via CAN communication and the P position input by
detent switch
Vehicle speed (5 km/h or more) is detected continu-
ously for 10 seconds or more even if the shift posi-
tion is detected in P position when the power supply
position is in ON positionCheck shift position inputBL-170
PDU
[B2559]Internal malfunction is detected in PDU Replace PDUBL-172
START POW SUP CIRC
[B2560]Though the engine start operation is not performed,
starter relay in IPDM E/R is ONCheck starter power sup-
plyBL-172
LOW VOLTAGE
[B2562]Battery power supply input to Intelligent Key unit (8.8V
or less) is detected continuously for 1.5 seconds or
moreCheck battery low volt-
ageBL-175
HI VOLTAGE
[B2563]Battery power supply input to Intelligent Key unit (18V
or more) is detected continuously for 90 seconds or
moreCheck for battery high
voltageBL-176
NATS MALFUNCTION
[B2590]Malfunction is detected in immobilizer systemCheck (IVIS) NATS trou-
ble diagnosis procedureBL-265
Suspect Systems
[DTC]Diagnostic item is detected when... Repair work Reference page
Monitor item Content
DR REQ SW Indicates [ON/OFF] condition of door request switch (driver side).
AS REQ SW Indicates [ON/OFF] condition of door request switch (passenger side).
BD/TR REQ SW Indicates [ON/OFF] condition of trunk opener request switch.
ON POS Indicates [ON/OFF] condition of ignition switch in ON position.
ACC POS Indicates [ON/OFF] condition of ignition switch in ACC position.
DOOR STAT SW Indicates [ON/OFF] condition of door unlock sensor.
STOP LAMP SW Indicates [ON/OFF] condition of stop lamp switch.
P RANGE SW Indicates [ON/OFF] condition of park position switch.
TR CANCEL SW* Indicates [ON/OFF] condition of trunk cancel switch.
DOOR LOCK SIG* Indicates [ON/OFF] condition of door lock signal from Intelligent Key remote controller button.
DOOR UNLOCK SIG* Indicates [ON/OFF] condition of door unlock signal from Intelligent Key remote controller button.
KEYLESS TRUNK* Indicates [ON/OFF] condition of trunk open signal from Intelligent Key remote controller button.
KEYLESS PANIC* Indicates [ON/OFF] condition of panic alarm signal from Intelligent Key remote controller button.
BRAKE PEDAL
BR-7
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Revision: 2007 April2007 M35/M45
Removal and InstallationNFS000RU
COMPONENTS
WITHOUT PRE-CRASH SEAT BELT
WITH PRE-CRASH SEAT BELT
NOTE:
Clevis pin can be installed from both left and right.
PFIA0838E
1. Clevis pin 2. Snap pin 3. Stop lamp switch
4. Brake switch 5. Clip 6. Brake pedal assembly
7. Brake pedal pad
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
: Apply Multi-purpose grease.
PFIA0839E
1. Clevis pin 2. Brake pedal stroke sensor 3. Snap pin
4. Stop lamp switch 5. Brake switch 6. Clip
7. Brake pedal assembly 8. Brake pedal pad
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
: Apply Multi-purpose grease.
BR-8
BRAKE PEDAL
Revision: 2007 April2007 M35/M45
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
2. Remove steering column assembly. Refer to PS-13, "
STEERING COLUMN" .
3. Disconnect stop lamp switch and brake switch connector.
4. Remove stop lamp switch and brake switch from brake pedal assembly.
5. Disconnect brake pedal stroke sensor connector.(With pre-crash seat belt)
CAUTION:
Brake pedal stroke sensor is not detachable. Do not detach it.
6. Remove snap pin and clevis pin from clevis of brake booster.
7. Remove brake pedal assembly mounting nuts. Pull brake booster toward engine room to the extent that
does not deform brake tube.
8. Remove brake booster clevis from input rod.
9. Remove mounting bolt and then remove brake pedal assembly from vehicle.
INSPECTION AFTER REMOVAL
Check the items below. If any is found, replace brake pedal
assembly.
–Check brake pedal upper rivet for deformation.
–Make sure that joint length “L” of sub-bracket and sliding plate is
4 mm (0.16 in) or more.
–Check brake pedal for bend, damage, and cracks on the welded
parts.
Check clevis pin and plastic stopper for damage and deforma-
tion. If any is found, replace clevis pin.
INSTALLATION
Installation is the reverse order of removal. Tightening torques for brake pedal assembly mounting nuts and
bolt are referred to BR-7, "
COMPONENTS" . Tightening torque for lock nut is referred to BR-18, "COMPO-
NENTS" .
Adjust brake pedal height after installing brake pedal assembly to vehicle. Refer to BR-6, "Inspection and
Adjustment" .
SFIA2487E
SBR997
BR-22
FRONT DISC BRAKE
Revision: 2007 April2007 M35/M45
FRONT DISC BRAKEPFP:41000
On-Board InspectionNFS000SC
PAD WEAR INSPECTION
Check pad thickness from an inspection hole on cylinder body.
Check using a scale if necessary.
ComponentsNFS000SD
WARNING:
Clean dust on caliper and brake pad with a vacuum dust collector to minimize the hazard of air borne
particles or other materials.
CAUTION:
While removing cylinder body, do not depress brake pedal because piston will pop out. Standard thickness : 11.0 mm (0.433 in)
Repair limit thickness : 2.0 mm (0.079 in)
MAA0439D
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
3: Apply polyglycol ether based lubricant.
: Apply brake fluid.
PFIA0820E
FRONT DISC BRAKE
BR-23
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Revision: 2007 April2007 M35/M45
It is not necessary to remove bolts on torque member and brake hose except for disassembly or
replacement of caliper assembly. In this case, hang cylinder body with a wire so as not to stretch
brake hose.
Do not damage piston boot.
If any shim is subject to serious corrosion, replace it with a new one.
Always replace shim and shim cover as a set when replacing brake pads.
Keep rotor free from brake fluid.
Burnish the brake pads and disc rotor mutually contacting surfaces, after refinishing or replacing
rotors, after replacing pads, or if a soft pedal occurs at very low mileage. Refer to BR-27, "
BRAKE
BURNISHING PROCEDURE" .
Removal and Installation of Brake PadNFS000SE
REMOVAL
1. Remove tires from vehicle with power tool.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers,
shims, and shim cover from torque member.
CAUTION:
When removing the pad retainer from the torque member,
lift it in the direction indicated by the arrow in the figure so
that it does not deform.
INSTALLATION
1. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease to between pad and shim. Install shim,
shim cover, to pad.
2. Apply PBC (Poly Butyl Cuprysil) grease or silicone-based
grease to between pad retainer and pad. Install pad retainers
and pads to torque member.
CAUTION:
Securely assemble pad retainers so that they are not
being lifted up from torque member.
Both inner and outer pads have a pad return system on
the pad retainer. Install pad return lever securely to pad
wear sensor.
3. Install cylinder body to torque member.
CAUTION:
In the case of replacing a pad with new one, check a brake fluid level in the reservoir tank because
brake fluid returns to master cylinder reservoir tank when pressing piston in.
NOTE:
Use a disc brake piston tool (commercial service tool) to easily press piston.
4. Install lower sliding pin bolt, and tighten it to the specified torque. Refer to BR-22, "
Components" .
5. Check front disc brake for drag.
6. Install tires to vehicle.
SBR556E
SBR557E
BR-28
REAR DISC BRAKE
Revision: 2007 April2007 M35/M45
REAR DISC BRAKEPFP:44000
On-Board InspectionNFS000SH
PAD WEAR INSPECTION
Check pad thickness from an inspection hole on cylinder body.
Check using a scale if necessary.
ComponentsNFS000SI
Standard
Standard thickness : 8.5 mm (0.335 in)
Repair limit thickness : 2.0 mm (0.079 in)
BRA0010D
1. Union bolt 2. Brake hose 3. Copper washer
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Cylinder body 8. Piston seal 9. Piston
10. Piston boot 11. Retaining ring 12. Inner shim cover
13. Inner shim 14. Inner pad 15. Pad retainer
16. Outer pad 17. Outer shim 18. Sliding pin boot
19. Bushing 20. Torque member mounting bolt 21. Washer
22. Torque member 23. Pad wear sensor 24. Inner pad (RH)
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
1: Apply rubber grease.
2: Apply PBC (Poly Butyl Cuprysil) grease or silicone-based grease.
PFIA0705J
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION BRC
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BRC
Revision: 2007 April2007 M35/M45
BRAKE CONTROL SYSTEM
VDC/TCS/ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 5
ON-VEHICLE SERVICE ............................................. 6
Adjustment of Steering Angle Sensor Neutral Posi-
tion ........................................................................... 6
SYSTEM DESCRIPTION ............................................ 7
System Diagram ....................................................... 7
Functions .................................................................. 7
ABS ....................................................................... 7
EBD ....................................................................... 7
TCS ....................................................................... 8
VDC ....................................................................... 8
ECD ....................................................................... 8
Operation That Is Not "System Error" ...................... 8
ABS ....................................................................... 8
TCS ....................................................................... 8
VDC ....................................................................... 8
Hydraulic Circuit Diagram ........................................ 9
CAN Communication ................................................ 9
SYSTEM DESCRIPTION ...................................... 9
TROUBLE DIAGNOSIS ............................................ 10
Fail-Safe Function .................................................. 10
ABS, EBD SYSTEM ............................................ 10
VDC/TCS ............................................................ 10
How to Perform Trouble Diagnoses ....................... 10
BASIC CONCEPT ............................................... 10
DIAGNOSIS FLOW CHART ................................ 11
ASKING COMPLAINTS ...................................... 12
EXAMPLE OF DIAGNOSIS WORKSHEET ........ 12
Component Parts Location ..................................... 13
Schematic .............................................................. 14Wiring Diagram — VDC — ..................................... 15
Control Unit Input/Output Signal Standard ............. 21
REFERENCE VALUE FROM CONSULT-II ......... 21
CONSULT-II Functions (ABS) ................................ 23
CONSULT-II MAIN FUNCTION ........................... 23
CONSULT-II SETTING PROCEDURE ................ 23
Self-Diagnosis ........................................................ 24
OPERATION PROCEDURE ................................ 24
ERASE MEMORY ............................................... 24
DISPLAY ITEM LIST ........................................... 25
Data Monitor ........................................................... 28
OPERATION PROCEDURE ................................ 28
DISPLAY ITEM LIST ........................................... 28
Active Test .............................................................. 30
OPERATION PROCEDURE ................................ 30
TEST ITEMS ....................................................... 31
For Fast and Accurate Diagnosis ........................... 32
PRECAUTIONS FOR DIAGNOSIS ..................... 32
Basic Inspection ..................................................... 33
BASIC INSPECTION 1: BRAKE FLUID LEVEL,
LEAK INSPECTION AND BRAKE PAD .............. 33
BASIC INSPECTION 2: LOOSENESS OF
POWER SYSTEM TERMINALS AND BATTERY ... 33
BASIC INSPECTION 3: ABS WARNING LAMP,
BRAKE WARNING LAMP, VDC OFF INDICATOR
LAMP AND SLIP INDICATOR LAMP .................. 33
TROUBLE DIAGNOSIS FOR SYSTEM .................... 34
Wheel Sensor Circuit .............................................. 34
INSPECTION PROCEDURE .............................. 34
Engine System ....................................................... 36
INSPECTION PROCEDURE .............................. 36
ABS Actuator and Electric Unit (Control Unit) ........ 36
INSPECTION PROCEDURE .............................. 36
ABS Actuator and Electric Unit (Control Unit) Power
Supply and Ground Circuit ..................................... 37
INSPECTION PROCEDURE .............................. 37
ABS Motor and Motor Relay Circuit ........................ 38
INSPECTION PROCEDURE .............................. 38
Solenoid, VDC Change-Over Valve and Actuator
Relay Circuit ........................................................... 39