ESP NISSAN X-TRAIL 2003 Service Repair Manual

FOREWORD
This manual contains maintenance and repair procedures for the NISSAN
X-TRAIL, model T30 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in speci-
fications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a man-
ner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first be completely satisfied that neither personal safety nor the vehicle's
safety will be jeopardized by the service method selected.
NISSAN EUROPE S.A.S.
Service Operations SectionParis, France

GI-4
PRECAUTIONS

General PrecautionsEAS000FQ

Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.

Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.

When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.

Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.

If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.

To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.

Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.

Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.

Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.

Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.

Replace inner and outer races of tapered roller bearings and needle bearings as a set.

Arrange the disassembled parts in accordance with their assembled locations and sequence.

Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.

After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.

Use only the fluids and lubricants specified in this manual.
SGI285
SGI231
SEF289H
SGI233

GI-14
HOW TO USE THIS MANUAL

How to Read Wiring DiagramsEAS000G4
CONNECTOR SYMBOLS
Most of connector symbols in wiring diagrams are shown from the terminal side.

Connector symbols shown from the terminal side are enclosed
by a single line and followed by the direction mark.

Connector symbols shown from the harness side are enclosed
by a double line and followed by the direction mark.

Certain systems and components, especially those related to
OBD, may use a new style slide-locking type harness connector.
For description and how to disconnect, refer to PG section,
“Description”, “HARNESS CONNECTOR”.

Male and female terminals
Connector guides for male terminals are shown in black and
female terminals in white in wiring diagrams.
SAIA0257E
SGI363

HOW TO USE THIS MANUAL
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14 Wire color

This shows a code for the color of the wire.
B = Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
LG = Light GreenBR = Brown
OR or O = Orange
P = Pink
PU or V (Violet) = Purple
GY or GR = Gray
SB = Sky Blue
CH = Dark Brown
DG = Dark Green
When the wire color is striped, the base color is given first, followed by the stripe color as shown
below:
Example: L/W = Blue with White Stripe
15 Option description

This shows a description of the option abbreviation used on the page.
16 Switch

This shows that continuity exists between terminals 1 and 2 when the switch is in the A posi-
tion. Continuity exists between terminals 1 and 3 when the switch is in the B position.
17 Assembly parts

Connector terminal in component shows that it is a harness incorporated assembly.
18 Cell code

This identifies each page of the wiring diagram by section, system and wiring diagram page
number.
19 Current flow arrow

Arrow indicates electric current flow, especially where the direction of standard flow (vertically
downward or horizontally from left to right) is difficult to follow.

A double arrow “ ” shows that current can flow in either direction depending on cir-
cuit operation.
20 System branch

This shows that the system branches to another system identified by cell code (section and
system).
21 Page crossing

This arrow shows that the circuit continues to another page identified by cell code.

The C will match with the C on another page within the system other than the next or preced-
ing pages.
22 Shielded line

The line enclosed by broken line circle shows shield wire.
23Component box in
wave line

This shows that another part of the component is also shown on another page (indicated by
wave line) within the system.
24 Component name

This shows the name of a component.
25 Connector number

This shows the connector number.

The letter shows which harness the connector is located in.

Example: M : main harness. For detail and to locate the connector, refer to PG section "Main
Harness", “Harness Layout”. A coordinate grid is included for complex harnesses to aid in
locating connectors.
26 Ground (GND)

The line spliced and grounded under wire color shows that ground line is spliced at the
grounded connector.
27 Ground (GND)

This shows the ground connection. For detailed ground distribution information, refer to
"Ground Distribution" in PG section.
28 Connector views

This area shows the connector faces of the components in the wiring diagram on the page.
29 Common component

Connectors enclosed in broken line show that these connectors belong to the same compo-
nent.
30 Connector color

This shows a code for the color of the connector. For code meaning, refer to wire color codes,
Number 14 of this chart.
31Fusible link and fuse
box

This shows the arrangement of fusible link(s) and fuse(s), used for connector views of
"POWER SUPPLY ROUTING" in PG section.
The open square shows current flow in, and the shaded square shows current flow out.
32 Reference area

This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors
(J/C) exists on the PG section. Refer to "Reference Area" for details. Num-
berItem Description

CONSULT-II CHECKING SYSTEM
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CONSULT-II CHECKING SYSTEMPFP:00000
DescriptionEAS000G8

CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the
vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various
kinds of diagnostic tests.

Refer to “CONSULT-II Software Operation Manual” for more information.
Function and System Application EAS000G9
x: Applicable
*1: Nissan Anti-Theft System
*2: Gasoline engine models
Nickel Metal Hydride Battery Replacement EAS000GA
CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following:
WARNING:
Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another bat-
tery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if
mistreated. Do not recharge, disassemble or dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regulations.
Diagnostic test
modeFunction
ENGINE
A/T
AIR BAG
ABS
ABS (Including ESP)
ALL MODE 4WD
NATS*1
Work supportThis mode enables a technician to adjust some devices faster and more
accurately by following the indications on CONSULT-II.x*2x--x - -
Self-diagnostic
resultsSelf-diagnostic results can be read and erased quickly. x x x x x x x
Trouble diagnos-
tic recordCurrent self-diagnostic results and all trouble diagnostic records previously
stored can be read.--x-- - -
Data monitor Input/Output data in the ECM can be read. x x - x x x -
Active testDiagnostic Test Mode in which CONSULT-II drives some actuators apart
from the ECMs and also shifts some parameters in a specified range.x--xxx -
CAN diagnosis
support monitorIndicates the communication condition of CAN communication line. x x - x x x -
DTC confirmationThe results of SRT (System Readiness Test) and the self-diagnosis status/
result can be confirmed.x*
2--- - - -
DTC work support Select the operating condition to confirm Diagnosis Trouble Codes. - x - - - - -
ECM (ECU/TCM)
part numberECM (ECU/TCM) part number can be read. x x - x x x -
ECU discrimi-
nated No.Classification number of a replacement ECU can be read to prevent an
incorrect ECU from being installed.--x-- - -
Function testConducted by CONSULT-II instead of a technician to determine whether
each system is “OK” or “NG”.xxxx x - -
Control unit initial-
izationAll registered ignition key IDs in NATS components can be initialized and
new IDs can be registered.---- - - x

FUEL INJECTOR AND FUEL TUBE
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b. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
c. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube.
CAUTION:

Pull quick connector holding “A” position in the figure.

Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Keep parts away from heat source. Especially, be careful when welding is performed around
them.

Do not expose parts to battery electrolyte or other acids.

Do not bend or twist connection between quick connector and fuel feed hose during installa-
tion/removal.

To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
4. Remove PCV hose. Refer to EM-17, "
Removal and Installation (QR20DE)" .
5. Disconnect harness connector from ignition coil.
6. Remove sub-harness for fuel injector.
7. Remove electric throttle control actuator and intake manifold support. Refer to EM-17, "
Removal and
Installation (QR20DE)" .
8. Loosen mounting bolts in reverse order as shown in the figure.
9. Remove fuel tube protector.
10. Pull out fuel tube and fuel injector assembly rearward of engine.
CAUTION:

When removing, be careful to avoid any interference with fuel injector.

Use a shop cloth to absorb any fuel leaks from fuel tube.
KBIA0702E
PBIC2205E
PBIC2180E

EM-38
[QR]
FUEL INJECTOR AND FUEL TUBE

b. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
c. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube.
CAUTION:

Pull quick connector holding “A” position in the figure.

Do not pull with lateral force applied. O-ring inside quick
connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Keep parts away from heat source. Especially, be careful when welding is performed around
them.

Do not expose parts to battery electrolyte or other acids.

Do not bend or twist connection between quick connector and fuel feed hose during installa-
tion/removal.

To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
4. Remove intake manifold collector. Refer to EM-20, "
Removal and Installation (QR25DE)" .
5. Disconnect sub-harness for fuel injector.
6. Loosen mounting bolts in reverse order as shown in the figure.
7. Remove fuel tube and fuel injector assembly and insulators.
CAUTION:

When removing, be careful to avoid any interference with
fuel injector.

Use a shop cloth to absorb any fuel leaks from fuel tube.
KBIA0702E
PBIC2205E
KBIA0239E

TIMING CHAIN
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INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the com-
ponents installed.
1. Make sure that crankshaft key points straight up.
2. Tighten mounting bolts in numerical order as shown in figure
with the following procedure, and install balancer unit.
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to EM-48, "
INSPECTION AFTER
REMOVAL" .
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten all bolts.
c. Turn all bolts 90 degrees clockwise (angle tightening).
d. Completely loosen.
CAUTION:
In this step, loosen bolts in reverse order as shown in the
figure.
e. Tighten all bolts.
f. Turn them another 90 degrees clockwise (angle tightening).
CAUTION:
Check tightening angle with an angle wrench (special service tool) or a protractor. Do not make
judgment by visual check alone.
PBIC2182E
: 48.1 N·m (4.9 kg-m, 35 ft-lb)KBIA0122E
: 0 N·m (0 kg-m, 0 ft-lb)
: 48.1 N·m (4.9 kg-m, 35 ft-lb)
KBIA0080E

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CYLINDER HEAD

–If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.

If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gas-
kets.
7. After inspection is completed, install removed parts.
8. Start engine, and confirm that engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-73, "
TROUBLE DIAGNOSIS" (WITH
EURO-OBD) or EC-520, "
TROUBLE DIAGNOSIS" (WITHOUT EURO-OBD).
Removal and InstallationEBS00KNQ
REMOVAL
1. Release fuel pressure. Refer to EC-48, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
2. Drain engine coolant and engine oil. Refer to CO-9, "
Changing Engine Coolant" and LU-8, "Changing
Engine Oil" .
3. Remove the following components and related parts.

Exhaust manifold and three way catalyst assembly; Refer to EM-23, "EXHAUST MANIFOLD AND
THREE WAY CATALYST" .

Intake manifold and fuel tube assembly (QR20DE); Refer to EM-17, "Removal and Installation
(QR20DE)" .

Intake manifold collector, intake manifold and fuel tube assembly (QR25DE); Refer to EM-20, "Removal
and Installation (QR25DE)" .

Water control valve and housing (water outlet); Refer to CO-22, "THERMOSTAT AND WATER CON-
TROL VALVE" .
NOTE:
Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to EM-44, "
TIMING CHAIN" .
5. Remove camshafts. Refer to EM-53, "
CAMSHAFT" .
6. Securely support bottom of cylinder block with a jack or equivalent tool, and release the hoist that was
supporting it.
1. Cylinder head assembly 2. Cylinder head gasket 3. Cylinder head bolt
PBIC2185E

ENGINE ASSEMBLY
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Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Release fuel pressure. Refer to EC-48, "
FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-510,
"FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD).
3. Disconnect both battery terminals. Refer to SC-3, "
BATTERY" .
4. Drain engine coolant from radiator. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
5. Remove the following parts.

LH and RH undercovers

Front road wheels and tyres

Battery; Refer to SC-3, "BATTERY" .

Drive belt; Refer to EM-13, "DRIVE BELTS" .

Air duct and air cleaner case assembly; Refer to EM-15, "AIR CLEANER AND AIR DUCT" .

Alternator; Refer to SC-12, "CHARGING SYSTEM" .

Radiator and radiator cooling fan assembly; Refer to CO-12, "RADIATOR" .
6. Disconnect engine room harness from the engine side and set it aside for easier work.
7. Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine Room LH
1. Disconnect fuel feed hose, and plug it to prevent fuel from draining. Refer to EM-32, "FUEL INJECTOR
AND FUEL TUBE"
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
3. Disconnect control cable from transaxle (A/T models). Refer to AT- 4 0 4 , "
ON-VEHICLE SERVICE" .
4. Disconnect clutch operating cylinder from transaxle, and move it aside (M/T models). Refer to CL-10,
"OPERATING CYLINDER" .
5. Disconnect shift and select cable from transaxle (M/T models). Refer to MT-14, "
CONTROL LINKAGE" .
Engine Room RH
1. Remove engine coolant reservoir tank. Refer to CO-12, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on vehicle side with a
rope to avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-2, "EXHAUST SYSTEM" .
2. Remove propeller shaft. Refer to PR-3, "
REAR PROPELLER SHAFT" .
3. Remove steering lower joint from steering gear. Refer to PS-10, "
STEERING COLUMN" .
4. Disconnect power steering fluid piping at a point between vehicle and engine. Refer to PS-34, "
HYDRAU-
LIC LINE" .
5. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter
(A/T models). Refer to EM-25, "
OIL PAN AND OIL STRAINER" and AT- 4 1 3 , "REMOVAL AND INSTALLA-
TION" .
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-17, "
TRAN-
SAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 , "REMOVAL AND INSTALLATION" (A/T models).
7. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-45, "
WHEEL SEN-
SORS" (ABS) or BRC-116, "WHEEL SENSORS" (ESP/TCS/ABS).
8. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on
vehicle side with a rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
9. Remove lower ends of left and right strut from steering knuckle. Refer to FSU-5, "
FRONT SUSPENSION
ASSEMBLY" .
Removal
1. Install engine slingers into front left of cylinder head and rear right of cylinder head.