engine NISSAN X-TRAIL 2003 Electronic Repair Manual

BRC-116
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
Symptom 7: SLIP Indicator Lamp Does Not Illuminate
EFS001AY
Inspection procedure
1.SLIP INDICATOR LAMP BURNED-OUT BULB INSPECTION
Check for continuity between the power supply terminal of meter and terminal of ABS warning lamp.
Is inspection result OK?
OK >> GO TO 2.
NG >> Circuit malfunction in SLIP indicator lamp or combination meter
2.SLIP INDICATOR LAMP POWER CIRCUIT INSPECTION
Disconnect the meter connector. Check that the voltage between the vehicle-side harness terminal and body
ground is battery voltage (Approx. 12V).
Is inspection result OK?
YES >> GO TO 3.
NO >>
lFuse inspection
lInspection for harness and connectors between fuse block and meter
lCheck the power supply circuit (battery and ignition switch circuit).
3.SLIP INDICATOR LAMP HARNESS INSPECTION
1. Disconnect connectors for the ESP/TCS/ABS control unit and meter vehicle-side harness.
2. Check the harness between the meter and the ESP/TCS/ABS control unit for an open/shorted circuit.
Is inspection result OK?
OK >> GO TO 4.
NG >> Repair or replace the disconnected harness.
4.SLIP INDICATOR LAMP CONNECTOR INSPECTION
Check connectors for the ESP/TCS/ABS control unit and meter vehicle-side harness.
Is inspection result OK?
YES >> Connect connectors, and perform the self-diagnosis. The vehicle harness has the intermediate
connector. Refer to the vehicle wiring diagram, always check it.
NG >> Repair or replace the disconnected connector.
Symptom 8: During ESP/TCS/ABS Control, Vehicle Behavior is Jerky.EFS001AZ
Inspection procedure
1.ENGINE SPEED SIGNAL INSPECTION
Perform²DATA MONITOR²with CONSULT-II for the ESP/TCS/ABS control unit.
Is the engine speed at idle 400 rpm or higher?
YES >> Normal
NO >> GO TO 2.
2.SELF-DIAGNOSIS RESULT CHECK 1
Perform the ESP/TCS/ABS control unit self-diagnosis.
Is the self-diagnosis results displayed?
YES >> After checking and repairing the applicable item, perform the ESP/TCS/ABS control unit self-
diagnosis again.
NO >> GO TO 3.

TROUBLE DIAGNOSIS
BRC-117
[ESP/TCS/ABS]
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BRC
3.ECM SELF-DIAGNOSIS RESULT CHECK
Perform the ECM self-diagnosis.
Is the self-diagnosis results indicated?
YES >> Repair or replace the camshaft position sensor system.
NO >> GO TO 4.
4.SELF-DIAGNOSIS RESULT 2
Disconnect connectors for the ESP/TCS/ABS control unit and ECM, and reconnect them correctly to perform
the self-diagnosis again.
Is inspection result OK?
OK >> GO TO 5.
NG >> Connector malfunction. Repair or replace the connector.
5.SELF-DIAGNOSIS RESULT CHECK 3
Perform the 4WD control unit self-diagnosis.
Is inspection result OK?
OK >> GO TO 6.
NG >> Repair or replace the applicable part.
6.SELF-DIAGNOSIS RESULT CHECK 4
Perform the ESP/TCS/4WD control unit self-diagnosis again.
Is the self-diagnosis results displayed?
YES >> Repair or replace the applicable item.
NO >> GO TO 7.
7.CIRCUIT CHECK BETWEEN ESP/TCS/ABS CONTROL UNIT AND ECM
1. Disconnect connectors for the ESP/TCS/ABS control unit and ECM.
2. Check the engine speed signal harness between the ESP/TCS/ABS control unit and ECM for an open/
shorted circuit.
3. Check connectors for the ESP/TCS/ABS control unit and ECM.
Is inspection result OK?
OK >> Inspection End
NG >> Repair or replace the applicable item and perform the ESP/TCS/ABS control unit self-diagnosis
again.

CL-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartECS004JZ
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8CL-9CL-11
Refer to EM section.EM-61
,EM-184
CL-13CL-15CL-15CL-15CL-15CL-15CL-15CL-15CL-15CL-16CL-16CL-16CL-16
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutchdoesnotdisengage 1234 55555 5667

CL-6
CLUTCH PEDAL
FREE PLAY INSPECTION
lPress the clutch pedal by hand until certain resistance can be
felt. Using a scale, check that the free play is within the specified
range.
CLEARANCE CHECK
1. Start the engine and let it idle.
2. Apply parking brake.
3. Depress the brake pedal.
4. Fully depress clutch pedal and shift to 1st gear.
5. Release clutch pedal gradually. Stop releasing the pedal at the
point where the clutch is about to be engaged. Using a scale,
check the clearance between the clutch pedal and floor panel to
see if it is within the specified range.
NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point.Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify they the inspection.
Removal and InstallationECS001WC
NOTE:
Install clutch pedal assembly and adjust the pedal height. Tighten stopper bolt to the specified torque.Pedalfreeplay :9-16mm(0.35-0.63in)
MAA0023D
Pedal height when the clutch disengages:
85 mm (0.335 in) or more
MAA0024D
SCIA0337E
1 Pedal bracket assembly 2 Fulcrum pin 3 Clutch switch
4 Stopper bolt 5 Lock nut 6 Bushing
7 Bushing 8 Snap pin 9 Stopper rubber
10 Clutch pedal 11 Bushing 12 Clevis pin
13 Stopper rubber 14 Bushing 15 Assist spring

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Clutch cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (special service tool).
lCheck clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
lWorn thrust ring will generate a beating noise when tapped at
therivetwithahammer.
lBroken thrust ring will make a clinking sound when cover is
shaken up and down.
lIf a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disk contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1. Apply recommended Grease to clutch disk and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
2. Install clutch disk and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
4. Install manual transaxle. Refer toMT-16, "
Removal and Installation"
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
SCL466-C
Allowable flywheel runout:
Vehicles with QR20DE:EM-89, "
Flywheel Deflec-
tion"
Vehicles with
YD22DDTi:EM-208, "Flywheel Deflec-
tion"
AEM100
Engine type Tool number
QR20DE KV30100100
YD22DDTi ST20630000
Tightening torque:
First step : 9.9 - 19 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
Final step : 35 - 44 N·m (3.5 - 4.5 kg·m, 26 - 32 ft·lb)SCIA0909E

SERVICE DATA AND SPECIFICATIONS (SDS)
CL-17
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS004UY
Clutch Master CylinderECS004UZ
Clutch Operating CylinderECS004V0
Clutch DiskECS001WM
Clutch CoverECS001WN
Clutch PedalECS001WL
Type of clutch control Hydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Engine type QR20DE YD22DDTi
Model240
Facing size (outer dia. x inner dia.thick-
ness)240 x 160 x 3.5 (9.45 x 6.30 x 0.138)
Thickness of disc assembly with load7.85 - 8.35 mm (0.391 - 0.3287 in) with
4,904 N (500 kg,1,103lb)7.85 - 8.35 mm (0.3.91 - 0.3287 in) with
5,690 N (580.2 kg, 1,279 lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be
measured (mm)1.0 mm (0.04 in) or less/ 230 mm (9.06 in) dai.
Maximum allowable spline backlash 1.0 mm (0.04 in)
Engine type QR20DE YD22DDTi
Model240
Full-load 4904 N (500 kg, 1,103lb) 5,690 N (580.2 kg, 1,279 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.46 - 1.54 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
Engine type QR20DE YD22DDTi
Model240
Pedal height 161 - 171mm (6.34 - 6.73 in)
Pedal height at clutch disengagement 86.1 mm (3.390 in) or more 81.9 mm (3.224 in) or more
Pedal free play 9 - 16 mm (0.35 - 0.63 in)
Clearance between clutch switch
thread end and stopper rubber0.1 - 1.0 mm (0.04 - 0.004 in)

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTION
A
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ENGINE COOLING SYSTEM
QR20DE
PRECAUTIONS .......................................................... 3
Precautions For Liquid Gasket ................................. 3
REMOVAL OF LIQUID GASKET .......................... 3
LIQUID GASKET APPLICATION PROCEDURE..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Disassembly and Assembly Radiator Fan ............. 13
DISASSEMBLY ................................................... 13
ASSEMBLY ......................................................... 13
INSPECTION ......................................................... 13
CHECKING RADIATOR CAP .............................. 13
CHECKING RADIATOR ...................................... 14
RADIATOR (ALUMINUM TYPE) .............................. 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18WATER PUMP .......................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
INSPECTION AFTER INSTALLATION ................ 20
THERMOSTAT AND WATER CONTROL VALVE .... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23
Capacity .................................................................. 23
Thermostat ............................................................. 23
Water Control Valve ................................................ 23
Radiator .................................................................. 23
Tightening Torque ................................................... 23
YD22DDTi
PRECAUTIONS ........................................................ 24
Precautions For Liquid Gasket ............................... 24
REMOVAL AND LIQUID GASKET ...................... 24
LIQUID GASKET APPLICATION PROCEDURE... 24
PREPARATION ......................................................... 25
Special Service Tools ............................................. 25
OVERHEATING CAUSE ANALYSIS ........................ 26
Troubleshooting Chart ............................................ 26
COOLING SYSTEM .................................................. 28
Cooling Circuit ........................................................ 28
ENGINE COOLANT .................................................. 30
Inspection ............................................................... 30
LEVEL CHECK .................................................... 30
LEAK CHECK ...................................................... 30
Changing Engine Coolant ....................................... 30
DRAINING ENGINE COOLANT .......................... 30
REFILLING ENGINE COOLANT ......................... 31
FLUSHING COOLING SYSTEM ......................... 32
RADIATOR ................................................................ 33
Removal and Installation ........................................ 33

PRECAUTIONS
CO-3
[QR20DE]
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[QR20DE]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS009S9
REMOVAL OF LIQUID GASKET
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
lIn areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the gasket applied area.
CAUTION:
Ifforsomeunavoidablereasonatoolsuchasaflat-blade
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
gasket to the groove.
lAs for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
lWithin five minutes of gasket application, install the mating com-
ponent.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten after the installation.
lAfter 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
SEM164F

CO-6
[QR20DE]
OVERHEATING CAUSE ANALYSIS
Except cool-
ing system
parts mal-
function— OverloadonengineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp Symptom Check items

ENGINE COOLANT
CO-9
[QR20DE]
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ENGINE COOLANTPFP:KQ100
InspectionEBS009SD
LEVEL CHECK
lCheck if the reservoir tank coolant level within MIN to MAX when
engine is cool.
lAdjust coolant if too much or too little.
LEAK CHECK
lTo check for leakage, apply pressure to the cooling system with
atester.
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine CoolantEBS009SE
WA RN ING:
lTo avoid being scalded, never change the coolant when the engine is hot.
lWrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
lBe careful not to allow coolant to contact drive belts.
SMA412B
Testing pressure
: 157 kPa (1.57bar 1.6 kg/cm2,23psi)
SLC134B
PBIC0236E