NISSAN X-TRAIL 2003 Electronic Repair Manual

REAR DISC BRAKE
BR-27
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MA
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REAR DISC BRAKEPFP:44000
ComponentEFS0017X
WA RN ING:
lClean dust on brake caliper and pad with a vacuum dust collector. Do not blow with compressed
air.
CAUTION:
lNever depress brake pedal while removing cylinder body because the piston will pop out.
lDo not remove brake hose and torque member mounting bolts unless disassembling or replacing
caliper assembly. Hang the cylinder body with a wire so that the brake hose is not under tension.
lBe careful not to damage the piston boot. Do not allow brake fluid to get on the rotor.
lWhen replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
InspectionEFS0017Y
PAD WEAR INSPECTION
Check pad thickness by lifting vehicle, removing the wheel, and
looking through check hole on cylinder body.If necessary, use a
scale.
SFIA0330E
1 Pad retainer 2 Outer shim cover 3 Outer shim
4 Outer pad 5 Pad retainer 6 Inner pad
7 Inner shim 8 Inner shim cover 9 Sliding pin boot
10 Sliding pin 11 Sliding pin bolt 12 Cylinder body
13 Copper washer 14 Brake hose 15 Union bolt
16 Copper washer 17 Air bleeder 18 Piston seal
19 Piston 20 Retaining ring 21 Torque member
standard thickness : 8.5 mm (0.335 in)
pad wear limit : 2.0 mm (0.079 in)
BRA0010D

BR-28
REAR DISC BRAKE
Pad Replacement
EFS0017Z
REMOVAL
CAUTION:
When replacing brake pads, always replace inner shims, outer shims, and shim covers as a set.
1. Remove master cylinder reservoir tank cap.
2. Remove lower sliding pin bolt.
3. Hang cylinder body with a wire, and remove pads, pad retainers,
and shims.
INSTALLATION
1. Apply brake grease on back of the pad and both sides of the shim. Install inner shim and inner shim cover
to inner pad, outer shim to outer pad.
2. Install pad retainers to torque member and install pads.
3. Connect cylinder body to the torque member.
CAUTION:
When replacing pads with new ones, press piston in until the pads can be installed. Carefully mon-
itor brake master cylinder reservoir fluid level. Brake fluid will return, raising master cylinder res-
ervoir tank fluid level.
4. Insert lower sliding pin bolt and tighten to the specified torque.
5. Check brakes for drag.
BRB0302D
SBR042C

REAR DISC BRAKE
BR-29
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BR
Caliper Removal and InstallationEFS00180
REMOVAL
1. Connect a vinyl tube to the air bleeder.
2. Drain brake fluid gradually from air bleeder while depressing
brake pedal.
3. Remove brake hose connected to caliper assembly and union
bolts. Remove brake hose from caliper assembly.
4. Remove union bolts and torque member mounting bolts, and
remove caliper assembly.
5. Remove disc rotor.
INSTALLATION
CAUTION:
lRefill with new brake fluid “ DOT 3 or DOT 4”.
lNever reuse drained brake fluid.
1. Install disc rotor.
2. Install caliper assembly. Tighten mounting bolts to the specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and caliper assembly mounting surface.
Install caliper assembly.
3. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
lDo not reuse the copper washer for union bolts.
lSecurely assemble brake hose to protrusions on cylinder body.
4. Bleed air. Refer toBR-10, "
Bleeding Brake System".
Caliper Disassembly and AssemblyEFS00181
DISASSEMBLY
WA RN ING:
Be careful not to pinch your fingers in the piston.
CAUTION:
Be careful not to damage the cylinder inner wall.
1. Remove caliper assembly from vehicle.
2. Remove sliding pin from cylinder body. Then remove pads,
shims, shim covers, and pad retainers from caliper assembly.
3. Remove sliding pin boots from torque member.
4. Using a slotted screwdriver (as shown in the figure), remove pis-
ton seals.
SBR656
SBR028A

BR-30
REAR DISC BRAKE
5. Place a wooden block as shown in the figure. Blow air into union
bolt mounting hole to remove pistons and piston boots.
6. Using a slotted screwdriver, remove piston seals.
INSPECTION AFTER DISASSEMBLY
Cylinder Body
CAUTION:
Use new brake fluid to clean. Never use mineral oils such as gasoline or kerosene.
lCheck cylinder inner wall for corrosion, wear and damage. If corrosion, wear or damage is detected,
replace the cylinder body.
lMinor flaws caused by corrosion or foreign material can be removed by polishing the surface with fine
sandpaper. Replace the cylinder body, if necessary.
Torque Member
Check for wear, cracks and damage. If wear, cracks or damage is detected, replace the applicable part.
Piston
CAUTION:
The piston sliding surface is plated. Do not polish with sandpaper.
Check piston surface for corrosion, wear and damage. If corrosion, wear or damage is detected, replace the
applicable part.
Sliding Pin, Pin Bolt and Pin Boot
Check sliding pin and sliding pin boot for wear, damage and cracks. If corrosion, wear or damage is detected,
replace the applicable part.
DISC ROTOR INSPECTION
Visual Inspection
Check surface of the disc rotor for uneven wear, cracks and serious damage. If uneven wear, cracks or seri-
ous damage is detected, replace it.
Run Out Inspection
1. Using wheel nuts, fix the disc rotor to the wheels hub. (2 or more positions)
BRD0041D
SFIA0340E

REAR DISC BRAKE
BR-31
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2. Using a dial indicator, check run out.
CAUTION:
Before measuring, make sure that the axle endplay is 0 mm
(0 in).
3. If the run out is outside the limit, find the minimum run out point
by shifting the mounting positions of the disc rotor and wheel hub by one hole.
Thickness Inspection
Using a micrometer, check thickness of the disc rotor. If the thick-
ness is outside the standard, replace the disc rotor.
ASSEMBLY
CAUTION:
When assembling, do not use rubber grease.
1. Apply rubber lubricant to piston seals, and install them to cylin-
der body.
CAUTION:
Do not reuse piston seals.
2. Apply brake fluid to piston boots. Cover piston end with piston
boot. Install cylinder side lip on piston boot properly into groove
on cylinder body.
CAUTION:
Do not reuse piston boot.
3. Press piston into cylinder body by hand. Assemble piston side
lip on piston boot properly into groove on the piston.
CAUTION:
Press piston evenly and change pressing point to prevent
cylinder inner wall from being rubbed.Measurement point:
At a point 10 mm (0.39 in) from the outer
edge of the disc.
Run out limit:
0.07 mm (0.0028 in) or less
BRA0013D
Standard thickness : 16.0 mm (0.630 in)
Wear limit : 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions):
0.02 mm (0.0008 in) or less
SBR020B
SFIA0156E
SFIA0157E

BR-32
REAR DISC BRAKE
4. Fix piston boot with retaining ring.
CAUTION:
lBe sure boot is securely engaged in groove on cylinder
body.
lDo not reuse retaining ring.
5. Connect sliding pins and sliding pin boots to torque member.
6. Connect torque member to axle assembly and tighten mounting
bolts to specified torque.
CAUTION:
Wipe oil and grease on axle assembly washer seats and torque
member mounting surface. Install torque member to axle
assembly.
7. Connect pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque.
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer toBR-10, "
Bleeding Brake
System"
SFIA0158E

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-33
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BR
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEFS000CQ
Brake PedalEFS000CR
Check ValveEF S0 00 CS
Brake BoosterEFS000CT
Vacuum type
Front Disc BrakeEFS000CU
Front brakeBrake model AD31VD
Cylinder bore diameter 44.4´2(1.748´0.08)
Pad
Length x width x thickness132.0´52.5´11 . 0
(5.20´2.067´0.433)
Rotor outer diameter x thickness 280´28 (11.02´1.10)
Rear brakeBrake model ADV9VA
Cylinder bore diameter 34.9 (1.374)
Pad
Length x width x thickness83.0´33.0´8.5
(3.268´1.299´0.335)
Rotor outer diameter x thickness 292´16 (11.50´0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electronic control type
Brake booster Booster model C215T
Diaphragm diameterPrimary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid DOT 3 or DOT 4
Free play (at pedal top surface) 3 - 11 mm (0.12 - 0.43 in)
Looseness at clevis pin (at pedal top surface) 1 - 3 mm (0.04 - 0.12 in)
Brake pedal height (from dash panel top surface)M/T model 156 - 166 mm (6.14 - 6.54 in)
A/T model 164 - 174 mm (6.46 - 6.85 in)
Depressed pedal height under force of 490 N (50 kg,110.6 lb)
(from dash panel top surface)M/T model 80 mm (3.15 in) or more
A/T model 85 mm (3.35 in) or more
Clearance between threaded end of stop lamp switch and pedal stopper 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Vacuum leakage [at vacuum of 66.7 kPa (-500 mmHg, -19.69
inHg)]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 sec-
onds
Vacuum leakage [at vacuum of -66.7 kPa (-500 mmHg, -19.69
inHg)]Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 sec-
onds
Input rod installation standard dimension 125 mm (4.92 in)
Brake typeAD31VD
Brake padStandard thickness (new) 11 mm (0.43 in)
Repair limit thickness 2.0 mm (0.07 in)
Disc rotorStandard thickness (new) 28 mm (1.10 in)
Repair limit thickness 26 mm (1.02 in)
Runout limit 0.04 mm (0.0016 in)

BR-34
SERVICE DATA AND SPECIFICATIONS (SDS)
Rear Disc Brake
EFS000CV
Brake typeAD9VA
Brake padStandard thickness (new) 8.5 mm (0.335 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotorStandard thickness (new) 16 mm (0.63 in)
Repair limit thickness 14 mm (0.55 in)
Runout limit 0.07 mm (0.0028 in)

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION
A
B
BRC
BRAKE CONTROL SYSTEM
4WD/ABS
PRECAUTIONS .......................................................... 4
Precautions for brake system ................................... 4
Precautions for brake control ................................... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
ALL MODE 4X4 SYSTEM .......................................... 6
System Description .................................................. 6
ABS FUNCTION ................................................... 6
4WD FUNCTION ................................................... 6
Control System Diagram .......................................... 6
TROUBLE DIAGNOSIS .............................................. 7
Fail-safe Function ..................................................... 7
How to Proceed with Trouble Diagnosis .................. 7
BASIC CONCEPT ................................................. 7
DIAGNOSIS FLOW ............................................... 8
ASKING COMPLAINTS ........................................ 9
TROUBLE DIAGNOSIS SHEET - EXAMPLE ....... 9
Component Parts Location ..................................... 10
Schematic ...............................................................11
Wiring Diagram — ABS — ..................................... 12
Trouble Diagnosis Chart by Symptom .................... 18
4WD/ABS Control Unit Input/Output Signal Stan-
dard ........................................................................ 19
4WD/ABS CONTROL UINT CONNECTOR TER-
MINAL ARRANGEMENT .................................... 19
REFERENCE STANDARD TABLE ..................... 19
CONSULT-II Functions ........................................... 23
CONSULT-II FUNCTION APPLICATION TABLE... 23
SELF-DIAGNOSIS .............................................. 24
DATA MONITOR ................................................. 26
ACTIVE TEST ..................................................... 29
Component Inspection ........................................... 30
ABS ACTUATOR ................................................ 30
4WD SOLENOID VALVE .................................... 32
Basic Inspection ..................................................... 32
BASIC INSPECTION 1 BRAKE FLUID LEVEL
AND LEAKAGE INSPECTION ............................ 32
BASIC INSPECTION 2 INSPECTION FOR
LOOSE POWER SUPPLY TERMINAL ............... 32BASIC INSPECTION 3 ABS/4WD WARNING
LAMP INSPECTION ............................................ 32
Wheel Speed Sensor System ................................. 32
INSPECTION PROCEDURE .............................. 32
Control Module Power Supply System ................... 34
INSPECTION PROCEDURE .............................. 34
G -Sensor System (4WD models) .......................... 34
INSPECTION PROCEDURE .............................. 34
4WD SOLENOID, ACTUATOR RELAY SYSTEM... 35
4WD MODE SWITCH SYSTEM ............................. 37
Trouble Diagnoses for Symptoms .......................... 38
4WD INDICATOR LAMP DOES NOT COME ON
FORAPPROXIMATELY1SECONDWHENTHE
IGNITION SWITCH IS TURNED TO ON ............. 38
4WD WARNING LAMP DOES NOT ILLUMINATE
WITH IGNITION ON ............................................ 39
4WD WARNING LAMP DOES NOT GO OUT
SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP
GOES OUT) ........................................................ 39
HEAVY TIGHT-CORNER BRAKING SYMPTOM
OCCURS WHEN THE VEHICLE IS DRIVEN IN
AUTO MODE AND THE STEERING WHEEL IS
TURNED FULLY TO EITHER SIDE AFTER THE
ENGINE IS STARTED ......................................... 39
4WD MODES CANNOT BE SWITCHED AFTER
ENGINE IS STARTED ......................................... 41
WHILE DRIVING, 4WD WARNING LAMP
FLASHES RAPIDLY. (WHEN IT FLASHERSFOR
APPROX. ONE MINUTE, THEN DOES NOT
ILLUMINATE.) ..................................................... 41
WHILE DRIVING, 4WD WARNING LAMP
FLASHES SLOWLY. (WHEN IT CONTINUES TO
ILLUMINATE UNTIL ENGINE TURNS OFF.) ...... 41
VEHICLE DOES NOT ENTER 4WD MODE
EVEN THOUGH 4WD WARNING LAMP IS OFF.... 41
TIGHT-CONER BRAKING SYMPTOM OCCURS
WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF). ....................... 42
4WD ACTUATOR RELAY (4WD SOLENOID

BRC-2
ACTUATOR RELAY) TURNS ON/OFF FRE-
QUENTLY ............................................................ 42
ABS warning lamp does not illuminate. (ABS warn-
ing lamp does not come on when the ignition switch
is turned ON.) ......................................................... 42
ABS warning lamp illuminates with ignition ON, but
does not illuminates after a few seconds. (ABS
warning lamp has illuminated.) ............................... 42
4WD warning lamp does not illuminate with ignition
ON. ......................................................................... 43
4WD warning lamp does not go out several seconds
after engine is started. (Drive mode indicator lamp
goes out.) ................................................................ 43
Heavy tight-corner braking symptom occurs when
the vehicle is driven in AUTO mode and the steering
wheel is turned fully to either side after the engine
is started. ................................................................ 44
Drive modes cannot be switched after engine is
started. .................................................................... 45
Wheel driving, 4WD warning lamp flashes rapidly.
(When it flashes for Approx. one minute, then does
not illuminate.) ........................................................ 45
Wheel driving, 4WD warning lamp flashes slowly.
(When it continues to illuminate until engine turns
OFF.) ....................................................................... 45
Vehicle does not enter 4WD mode even though
4WD warning lamp is off. ........................................ 46
Tight-corner braking symptom occurs when the
vehicle is started in AUTO mode (4WD warning lamp
remain OFF). .......................................................... 46
E-TS actuator relay (4WD solenoid actuator relay)
turns ON/OFF frequently. ........................................ 46
Inspection of drive mode change-over switch path... 47
WHEEL SENSORS ................................................... 48
Removal and Installation ........................................ 48
G-SENSOR (4WD MODEL ONLY) ............................ 49
Removal and Installation ........................................ 49
SENSOR ROTOR ...................................................... 50
Removal and Installation ........................................ 50
REMOVAL ........................................................... 50
INSTALLATION .................................................... 50
ACTUATOR ............................................................... 51
Removal and Installation ........................................ 51
REMOVAL ........................................................... 51
INSTALLATION .................................................... 51
ESP/TCS/ABS
PRECAUTIONS ......................................................... 52
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................. 52
Precautions for Brake System ................................ 52
Precautions for Brake Control ................................ 52
Precautions for CAN System .................................. 53
FOR INSPECTION .............................................. 53
FOR HARNESS REPAIR .................................... 53ON-VEHICLE SERVICE ............................................54
Adjustment of Neutral Position of Steering Angle
Sensor .....................................................................54
GENERAL INFORMATION .......................................56
Fail-Safe ..................................................................56
ABS SYSTEM ......................................................56
ESP/TCS SYSTEM ..............................................56
Hydraulic Circuit ......................................................56
ABS Functions ........................................................56
TCS Functions ........................................................57
ESP Functions ........................................................57
System Diagram .....................................................58
CAN COMMUNICATION ...........................................59
System Description .................................................59
FOR M/T MODELS ..............................................59
TROUBLE DIAGNOSIS ............................................60
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ......................................................60
INTRODUCTION .................................................60
WORK FLOW ......................................................61
ASKING COMPLAINTS .......................................62
EXAMPLE OF DIAGNOSIS SHEET ....................62
Component Parts and Harness Connector Location... 63
Schematic ...............................................................64
Wiring Diagram —ESP/TCS/ABS— .....................65
Control Unit Input/Output Signal Standard ..............71
STANDARDS USING A CIRCUIT TESTER AND
OSCILLOSCOPE .................................................71
STANDARDS WITH CONSULT-II ........................75
Functions of CONSULT-II .......................................77
CONSULT-II MAINLY FUNCTION APPLICA-
TION TO ESP/TCS/ABS ......................................77
SELF-DIAGNOSIS ...............................................78
DATA MONITOR ..................................................81
ACTIVE TEST ......................................................84
For Correct and Quick Diagnosis ............................88
PRECAUTIONS FOR TROUBLE DIAGNOSIS ... 88
Basic Inspection ......................................................89
PRELIMINARY CHECK 1: (BRAKE FLUID
LEVEL AND LEAK INSPECTION) .......................89
PRELIMINARY CHECK 2: (INSPECTION FOR
LOOSE POWER SUPPLY TERMINAL) ...............89
PRELIMINARY CHECK 3: (INSPECTION FOR
ABS WARNING LAMP, ESP OFF INDICATOR
LAMP, AND SLIP INDICATOR LAMP) .................89
Inspection 1 Wheel Speed Sensor and Circuit .......90
Inspection 2 Engine System ...................................92
Inspection 3 ESP/TCS/ABS Control Unit System ...92
Inspection 4 Pressure Sensor and the Circuit
between Pressure Sensor and ESP/TCS/ABS Con-
trol Unit. ...................................................................93
Inspection 5 Steering Angle Sensor and the Circuit
between Steering Angle Sensor and ESP/TCS/ABS
Control Unit. ............................................................94
Inspection 6 Yaw Rate Sensor/ Side G sensor and
the Circuit between Yaw Rate Sensor/ Side G sen-
sor and ESP/TCS/ABS Control Unit. ......................95
Inspection 7 Solenoid Valve, ESP Switch-over Sole-