alternator NISSAN X-TRAIL 2003 Electronic Repair Manual

REFRIGERANT LINES
ATC-127
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With Diesel Engine
1. Using recycling and recovery equipment (for HFC-134a), discharge the refrigerant.
2. Remove the engine under cover.
3. Remove the compressor-alternator belt.
Refer to,EM-13, "
Removal and Installation"QR engine;E M - 111 , "Removal and Installation"YD engine.
4. Remove the mounting nuts (bolts) from the high-pressure flexi-
ble hose and low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Disconnect the compressor connector.
RHA667H
RJIA0073E
RJIA0579E

TROUBLE DIAGNOSIS
BRC-89
[ESP/TCS/ABS]
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BRC
ABS Warning Lamp, ESP OFF Indicator Lamp, SLIP Indicator Lamp ON/OFF Timing
´:ON –: Lamp OFF
´: Applicable
–: Not applicable
Basic InspectionEFS001A9
PRELIMINARY CHECK 1: (BRAKE FLUID LEVEL AND LEAK INSPECTION)
1. Check the fluid level in the brake reservoir tank. If the fluid level is low, refill the brake fluid.
2. Check the area around the brake piping, ESP/TCS/ABS actuator for leaks. If a leak or oozing is detected,
checkasfollows:
lIf the connections at the ESP/TCS/ABS actuator are loose, tighten the piping to the specified torque.
Then check again for leaks, and make sure that there is no fluid leak.
lIf the flare nuts at the connections and the threads of the ESP/TCS/ABS actuator are damaged, replace
the damaged parts. Then check again for leaks, and make sure that there is no fluid leak.
lIf a leak or oozing is detected on other parts than the ESP/TCS/ABS actuator connections, wipe the
applicable part with a clean cloth. Then check again for leaks, and if there is still a leak or oozing,
replace the damaged part.
lIf a leak or oozing is detected on the ESP/TCS/ABS actuator body, wipe the applicable part with a clean
cloth. Then check again for leaks, and if there is still a leak or oozing, replace the ESP/TCS/ABS actua-
tor body.
CAUTION:
Do not disassemble the actuator body.
3. Check the brake disc rotor and pads.
PRELIMINARY CHECK 2: (INSPECTION FOR LOOSE POWER SUPPLY TERMINAL)
Check the battery for looseness on the battery positive/negative terminals and ground connection. If loose-
ness is detected, tighten the piping to the specified torque. Check that the battery voltage does not drop and
the alternator is normal.
PRELIMINARY CHECK 3: (INSPECTION FOR ABS WARNING LAMP, ESP OFF INDICATOR
LAMP, AND SLIP INDICATOR LAMP)
1. Check that the ABS warning lamp is ON for Approx. 0.5 seconds when the ignition switch is turned ON. If
it does not turn on, check the ABS warning lamp and the circuit, and the combination meter.
2. Check that ESP OFF indicator lamp is ON for Approx. 0.5 seconds when the ignition switch is turned ON.
If it does not turn ON, check the ESP OFF indicator lamp and the circuit, and the combination meter.
3. Check that the SLIP indicator lamp is ON for Approx. 0.5 seconds when the ignition switch is turned ON. If
it does not turn ON, check the SLIP indicator lamp and the circuit.
Condition ABS warning lampESP OFF
indicator lampSLIP indicator lamp Remarks
When the ignition switch is
OFF––– –
After the ignition switch is
turned ON
For Approx. 0.5 seconds´´´–
Ignition switch ON
Approx. 0.5 seconds later––– –
When the ESP OFF switch
turns ON (ESP/TCS function
OFF).–´–Lamp goes off after Approx. 2
seconds when the engine re-start.
ESP/TCS/ABS
malfunction´´´–
´´–When the ESP/TCS/ABS control
unit is abnormal (power supply or
ground malfunction).
When the ESP/TCS ism
abnormal.–´´–

BRC-106
[ESP/TCS/ABS]
TROUBLE DIAGNOSIS
5.ESP/TCS/ABS CONTROL UNIT POWER SUPPLY CIRCUIT INSPECTION 2
1. Check the fuse 10A.
2. Check for continuity between the battery positive terminal and
the ESP/TCS/ABS control unit connector.
Is inspection result OK?
YES >> Check the battery for a loose terminal and low voltage or the alternator for abnormality.
NO >>
lReplace the fuse 10A.
lHarness disconnection
Inspection 12 When “EMERGENCY BRAKE” is indicated in the Self-Diagnosis
Results
EFS001AO
Inspection procedure
1.SELF-DIAGNOSIS RESULT CHECK
Check the self-diagnosis results.
When any items other than²EMERGENCY BRAKE²is displayed in the self-diagnosis results, follow the
instructions below.
CAUTION:
²EMERGENCY BRAKE²is indicated when the control unit itself is detected internal error. If this display
item was indicated, replace the control unit.
Is
²EMERGENCY BRAKE²is indicated in the self-diagnosis results?
>> Replace the ESP/TCS/ABS control unit, and perform the self-diagnosis again.
Inspection 13 When “ST ANG SEN SIGNAL” is Indicated in the Self-Diagnosis
Results
EFS001AP
Inspection procedure
1.SELF-DIAGNOSIS RESULT CHECK 1
Check the self-diagnosis results.
When any items other than
²ST ANGLE SEN SIGNAL²is displayed in the self-diagnosis results:
YES >> Check and repair the applicable items. Perform the self-diagnosis again.
NO >> Perform the steering angle sensor neutral position adjustment. GO TO 2.
SFIA0387E
ESP/TCS/ABS control unit
(Vehicle-side connector)Battery terminal Continuity
1 positive Yes
Self-diagnosis results
CONSULT-II indication item
EMERGENCY BRAKE
Self-diagnosis results
CONSULT-II indication item
ST ANGLE SEN SIGNAL

WATER PUMP
CO-19
[QR20DE]
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WATER P UM PPFP:21020
Removal and InstallationEBS009SJ
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.
REMOVAL
Water Pump Removal
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
2. Remove the following parts.
lEngine under cover
lAlternator, water pump and air compressor belt
Refer to drive beltEM-13, "
Removal and Installation".
3. Remove water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
Water Pump Housing Removal
1. Perform step 1 and 2 of “Water Pump Removal”.
2. Remove alternator.
3. Remove oil level gauge.
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
4. Remove bolts mounting water pipe.
5. Remove water pump housing.
Water Pipe Removal
1. Remove water pump housing.
KBIA0154E
1 Water pump 2 Gasket 3 Water pump housing
4 Water pipe

TROUBLE DIAGNOSIS
EC-71
[QR (WITH EURO-OBD)]
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EC
Air Air duct
55555 5EM-15
Air cleanerEM-15
Air leakage from air duct
(Mass air flow sensor —electric
throttle control actuator)
5555EM-15
Electric throttle control actuatorEM-17
Air leakage from intake manifold/
Collector/GasketEM-17
Cranking Battery
111111 11SC-3
Alternator circuitSC-12
Starter c irc uit 3SC-21
Signal plate 6EM-64
PNP switch
4MT-13or
AT- 1 3 5
Engine Cylinder head
55555 55 5EM-52
Cylinder head gasket 4 3
Cylinder block
66666 66 64
EM-64
Piston
Piston ring
Connecting rod
Bearing
Crankshaft
Va l v e
mecha-
nismTiming chain
55555 55 5EM-43
CamshaftEM-33
Intake valve
3EM-52
Exhaust valve
Exhaust Exhaust manifold/Tube/Muffler/
Gasket
55555 55 5EM-22
,EX-
2Three way catalyst
Lubrica-
tionOil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery/Oil cooler
55555 55 52EM-24
,LU-
9,LU-10,
LU-13
Oil level (Low)/Filthy oilLU-7
SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA

TROUBLE DIAGNOSIS
EC-419
[QR (WITHOUT EURO-OBD)]
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EC
Air Air duct
55555 5EM-15
Air cleanerEM-15
Air leakage from air duct
(Mass air flow sensor —electric
throttle control actuator)
5555EM-15
Electric throttle control actuatorEM-17
Air leakage from intake manifold/
Collector/GasketEM-17
Cranking Battery
111111 11SC-3
Alternator circuitSC-12
Starter c irc uit 3SC-21
Signal plate 6EM-64
PNP switch
4MT-13or
AT- 3 8 8
Engine Cylinder head
55555 55 5EM-52
Cylinder head gasket 4 3
Cylinder block
66666 66 64
EM-64
Piston
Piston ring
Connecting rod
Bearing
Crankshaft
Va l v e
mecha-
nismTiming chain
55555 55 5EM-43
CamshaftEM-33
Intake valve
3EM-52
Exhaust valve
Exhaust Exhaust manifold/Tube/Muffler/
Gasket
55555 55 5EM-22
,EX-
2Three way catalyst
Lubrica-
tionOil pan/Oil strainer/Oil pump/Oil
filter/Oil gallery/Oil cooler
55555 55 52EM-24
,LU-
9,LU-10,
LU-13
Oil level (Low)/Filthy oilLU-7
SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA

EC-794
[YD]
DTC P1660 BATTERY VOLTAGE
DTC P1660 BATTERY VOLTAGE
PFP:AYBGL
On Board Diagnosis LogicEBS0035A
The ECM checks if battery voltage is within the tolerance range for the engine control system.
DTC Confirmation ProcedureEBS0035B
With CONSULT-II
1. Check the following.
–Jumper cables are connected for jump starting.
–Battery or alternator has been replaced.
If the result is “Yes” for one item or more, skip the following steps and go toEC-794, "
Diagnostic Proce-
dure".
2. Check that the positive battery terminal is connected to battery properly. If NG, reconnect it properly.
3. Check that the alternator functions properly. Refer toSC-12, "
CHARGING SYSTEM".
4. Turn ignition switch “ON” and select “DATA MONITOR” mode with CONSULT-II.
5. Wait one minute.
6. If DTC is detected, go toEC-794, "
Diagnostic Procedure".
If DTC is not detected, go to next step.
7. Start engine and wait one minute at idle.
8. If DTC is detected, go toEC-794, "
Diagnostic Procedure".
Diagnostic ProcedureEBS0035C
1.INSPECTION START
Are jumper cables connected for the jump starting?
Ye s o r N o
Yes >>GOTO3.
No >> GO TO 2.
2.CHECK BATTERY AND ALTERNATOR
Check that the proper type of battery and alternator is installed.
Refer toSC-3, "
BATTERY",SC-12, "CHARGING SYSTEM".
OK or NG
OK >> GO TO 5.
NG >> Replace with a proper one.
DTC Malfunction is detected when ... Check Items (Possible Cause)
P1660
lAn abnormally high or low voltage from the battery
is sent to ECM.lIncorrect jump starting
lBattery
lAlternator
lECM

EM-3
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EMA ALTERNATOR AND WATER PUMP BELT ....... . 111
Removal and Installation ...................................... . 111
REMOVAL ......................................................... . 111
INSTALLATION ................................................. . 111
AIR CLEANER AND AIR DUCT .............................. 112
Removal and Installation ....................................... 112
REMOVAL .......................................................... 112
INSTALLATION .................................................. 112
CHANGING AIR CLEANER ELEMENT ............. 112
CHARGE AIR COOLER .......................................... 114
Removal and Installation ....................................... 114
REMOVAL .......................................................... 114
INSPECTION AFTER REMOVAL ...................... 114
INSTALLATION .................................................. 114
INTAKE MANIFOLD ................................................ 115
Removal and Installation ....................................... 115
REMOVAL .......................................................... 115
INSPECTION AFTER REMOVAL ...................... 116
INSTALLATION .................................................. 116
INSPECTION AFTER INSTALLATION .............. 117
CATALYST ............................................................... 118
Removal and Installation ....................................... 118
REMOVAL .......................................................... 118
INSTALLATION .................................................. 118
EXHAUST MANIFOLD AND TURBOCHARGER ... 119
Removal and Installation ....................................... 119
REMOVAL .......................................................... 119
INSTALLATION ................................................. 120
INSPECTION AFTER INSTALLATION ............. 120
Disassembly and Assembly ................................. 121
REMOVAL ......................................................... 121
INSPECTION AFTER REMOVAL ..................... 121
Turbocharger ........................................................ 122
ROTOR SHAFT CLEARANCE ......................... 122
ROTOR SHAFT END PLAY .............................. 122
TURBINE WHEEL ............................................. 123
COMPRESSOR WHEEL .................................. 123
WASTEGATE VALVE ACTUATOR ................... 123
TROUBLE DIAGNOSIS OF TURBOCHARGER. 123
OIL PAN AND OIL STRAINER ............................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSPECTION AFTER REMOVAL ..................... 127
INSTALLATION ................................................. 127
INSPECTION AFTER INSTALLATION ............. 129
GLOW PLUG .......................................................... 130
Removal and Installation ...................................... 130
REMOVAL ......................................................... 130
INSTALLATION ................................................. 130
VACUUM PUMP ..................................................... 131
Removal and Installation ...................................... 131
INSPECTION BEFORE REMOVAL .................. 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
INSPECTION AFTER INSTALLATION ............. 132
Disassembly and Assembly ................................. 133
DISASSEMBLY ................................................. 133
ASSEMBLY ....................................................... 133INJECTION TUBE AND FUEL INJECTOR ............135
Removal and Installation ......................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
INSPECTION AFTER INSTALLATION ..............137
FUEL SUPPLY PUMP .............................................138
Removal and Installation ......................................138
REMOVAL .........................................................138
INSPECTION AFTER REMOVAL .....................143
INSTALLATION .................................................143
ROCKER COVER ...................................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSTALLATION .................................................148
INSPECTION AFTER INSTALLATION ..............148
CAMSHAFT ............................................................149
Removal and Installation ......................................149
REMOVAL .........................................................149
INSPECTION AFTER REMOVAL .....................150
INSTALLATION .................................................153
Valve Clearance ...................................................154
INSPECTION ....................................................154
ADJUSTMENTS ................................................155
SECONDARY TIMING CHAIN ................................158
Removal and Installation ......................................158
REMOVAL .........................................................158
INSPECTION AFTER REMOVAL .....................160
INSTALLATION .................................................161
PRIMARY TIMING CHAIN ......................................163
Removal and Installation ......................................163
REMOVAL .........................................................165
INSPECTION AFTER REMOVAL .....................168
INSTALLATION .................................................168
CYLINDER HEAD ...................................................173
On-Vehicle Service ...............................................173
CHECKING COMPRESSION PRESSURE .......173
Removal and Installation ......................................174
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
Disassembly and Assembly ..................................178
DISASSEMBLY .................................................178
ASEMBLY ..........................................................179
INSPECTION AFTER DISASSEMBLY ..............179
ENGINE ASSEMBLY ..............................................184
Removal and Installation ......................................184
REMOVAL .........................................................184
INSTALLATION .................................................186
INSPECTION AFTER INSTALLATION ..............186
CYLINDER BLOCK ................................................188
Disassembly and Assembly ..................................188
DISASSEMBLY .................................................189
ASSEMBLY .......................................................193
How to Select Piston and Bearing ........................197
DESCRIPTION ..................................................197
HOW TO SELECT PISTON ..............................197
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................198

EM-14
[QR20DE]
DRIVE BELTS
2. Insert a rod approximately 6 mm (0.24in) in diameter through the rear of engine into holding boss to fix
tensioner pulley.
3. Hook auxiliary drive belt onto all pulleys except for water pump. Hook belt onto water pump pulley at the
end.
CAUTION:
Confirm belts are completely set to pulleys.
4. Release tensioner, and apply tensions to belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tensions of belt at indicator is within the allowable use range. Refer toEM-13, "
Checking Drive
Belts".
Removal and Installation of Auxiliary Drive Belt Auto- tensionerEBS009QR
REMOVAL
1. Remove front RH engine side cover.
2. Remove auxiliary drive belt.
lKeep tensioner pulley fixed with a tool such as a short-length screwdriver.
3. Remove alternator and then auxiliary drive belt auto-tensioner.
lRemove and install auxiliary drive belt auto-tensioner by fixing tension pulley.
INSTALLATION
lInstall in the reverse order of removal.
CAUTION:
Install auxiliary drive belt auto-tensioner carefully not to damage the water pump pulley.
KBIA0092E

EM-44
[QR20DE]
TIMING CHAIN
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove the parts listed below.
lEngine hood
lUndercover
lPCV hose
lIgnition coil; Refer toEM-27, "Removal and Installation".
lRocker cover; Refer toEM-31, "Removal and Installation".
lEngine coolant reservoir tank
lAuxiliary drive belt; Refer toEM-13, "Removal and Installation".
lAlternator
lAuxiliary drive belt auto-tensioner; Refer toEM-14, "Removal and Installation of Auxiliary Drive Belt
Auto- tensioner".
lExhaust front tube; Refer toEX-2, "EXHAUST SYSTEM".
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Move power steering pump with piping connected, and secure it to vehicle side temporarily.
5. Pull power steering reservoir tank out of brackets to move power steering piping.
CAUTION:
lTo avoid power steering fluid leakage, temporarily fix reservoir tank vertically.
6. Suspend engine with a hoist, and support the engine posture.
For installation of engine slingers, refer toEM-61, "
ENGINE ASSEMBLY"
7. Remove RH engine mount insulator.
8. Remove center member and rear engine mounting bracket.
9. Drain engine oil.
10. Remove oil pan upper and lower, and oil strainer. Refer toEM-24, "
Removal and Installation".
11. Remove Intake valve timing control cover.
a. Loosen bolts in reverse order shown in the figure.
b. Remove the cover using Tool (Seal cutter).
12. Pull chain guide between camshaft sprockets out through front
cover.
13. Set No.1 cylinder at TDC on its compression stroke with the fol-
lowing procedure.
a. Rotate crankshaft pulley clockwise and align mating marks to
timid indicator on front cover.
KBIA0085E
KBIA0190E