QUICK REFERENCE INDEX Edition: July 2008 A GENERAL INFORMATION Revision: October 2008 Publication No. SM9E-1N50U0 B ENGINE
C HYBRID D TRANSMISSION & DRIVELINE
E SUSPENSION
F BRAKES
G STEERING H RESTRAINTS
I
VENTILATION, HEATER & AIR CONDITIONER
J BODY INTERIOR
K BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
L DRIVER CONTROLS
All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc.
M ELECTRICAL & POWER CONTROL
N DRIVER INFORMATION & MULTIMEDIA
O CRUISE CONTROL P MAINTENANCE
GI EM LU CO EC FL EX STR ACC HBC HBB CL TM DLN FAX RAX FSU RSU SCS WT BR PB BRC ST STC SB SBC SR SRC VTL HA HAC INT IP SE ADP AP DLK SEC GW PWC RF EXT BRM MIR EXL INL WW DEF HRN PWO BCS LAN PCS CHG PG MWI WCS SN AV CCS MA
General Information Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Starting System Accelerator Control System Hybrid Control System Hybrid Battery System Clutch Transaxle & Transmission Driveline Front Axle Rear Axle Front Suspension Rear Suspension Suspension Control System Road Wheels & Tires Brake System Parking Brake System Brake Control System Steering System Steering Control System Seat Belt Seat Belt Control System SRS Airbag SRS Airbag Control System Ventilation System Heater & Air Conditioning System Heater & Air Conditioning Control System Interior Instrument Panel Seat Autodrive Positioner System Adjustable Pedals Door & Lock Security Control System Glass & Window System Power Window Control System Roof Exterior Body Repair Manual Mirrors Exterior Lighting System Interior Lighting System Wiper & Washer Defogger Horn Power Outlet Body Control System LAN System Power Control System Charging System Power Supply, Ground & Circuit Elements Meter, Warning Lamp & Indicator Warning Chime System Sonar System Audio, Visual & Navigation System Cruise Control System Maintenance
A B C D E F G H I J K L M N O P
FOREWORD This manual contains maintenance and repair procedure for the 2009 NISSAN XTERRA. 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 specifications 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 manner 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.
QUICK REFERENCE CHART: XTERRA
2009
QUICK REFERENCE CHART: XTERRA Engine Tune-up Data
INFOID:0000000003303250
GENERAL SPECIFICATIONS Cylinder arrangement
V-6
3
3,954 (241.30)
Displacement cm (cu in) Bore and stroke
95.5 × 92.0 (3.76 × 3.622)
mm (in)
Valve arrangement
DOHC
Firing order
1-2-3-4-5-6
Number of piston rings
Compression
2
Oil
1
Number of main bearings
4
Compression ratio
9.7
Compression pressure
kPa
(kg/cm2, psi)/300 rpm
Standard
1,275 (13.0, 185)
Minimum
981 (10.0, 142)
Differential limit between cylinders
98 (1.0, 14)
Cylinder number
SEM713A
Valve timing (Intake valve timing control - “OFF”)
PBIC0187E
Unit: degree a
b
c
d
e
f
244
240
−4
64
6
58
SPARK PLUG Make
NGK
Standard type
DILFR5A-11
Gap (nominal)
1.1 mm (0.043 in)
QUICK REFERENCE CHART: XTERRA
2009
Front Wheel Alignment (Unladen*1)*6 Drive type
Camber Degree minute (decimal degree)
2WD
4WD
Minimum
-0° 30′ (-0.50°)
-0° 15′ (-0.25°)
Nominal
0° 15′ (0.25°)
0° 30′ (0.50°)
Maximum
1° 0′ (1.00°)
1° 15′ (1.25°)
0° 45′ (0.75°) or less
0° 45′ (0.75°) or less
Minimum
2° 15′ (2.25°)
2° 0′ (2.00°)
Nominal
3° 0′ (3.00°)
2° 45′ (2.75°)
Maximum
3° 45′ (3.75°)
3° 30′ (3.50°)
0° 45′ (0.75°) or less
0° 45′ (0.75°) or less
Nominal
13° 0′ (13.00°)
12° 45′ (12.75°)
Minimum
3.0 mm (0.12 in)
3.0 mm (0.12 in)
Nominal
4.0 mm (0.16 in)
4.0 mm (0.16 in)
Maximum
5.0 mm (0.20 in)
5.0 mm (0.20 in)
Minimum
0° 7′ (0.12°)
0° 7′ (0.12°)
Nominal
0° 9′ (0.15°)
0° 9′ (0.15°)
Maximum
0° 11′ (0.18°)
Cross camber
Caster Degree minute (decimal degree)
Cross caster Kingpin inclination Degree minute (decimal degree)
INFOID:0000000003303254
SFA234AC
Distance (A − B) Total toe-in Angle (left wheel or right wheel) Degree minute (decimal degree)
Wheel turning angle (full turn)
0° 11′ (0.18°)
Inside Degree minute (Decimal degree)
2
33° 27′ – 35° 27′ * (33.45° – 35.45°)
33° 41′ – 35° 41′ *4 (33.68° – 35.68°)
Outside Degree minute (Decimal degree)
29° 25′ – 31° 25′ *3 (29.42° – 31.42°)
29° 57′ – 31° 57′ *5 (29.95° – 31.95°)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Target value 35° 27′ (35.45°) *3: Target value 31° 25′ (31.42°) *4: Target value 35° 41′ (35.68°) *5: Target value 31° 57′ (31.95°) *6: Some vehicles may be equipped with straight (non-adjustable) lower link bolts and washers. In order to adjust camber and caster on these vehicles, first replace the lower link bolts and washers with adjustable (cam) bolts and washers.
Rear Suspension Information Suspension type Shock absorber type
INFOID:0000000003303266
Rigid axle with semi-elliptic leaf springs Double-acting hydraulic
QUICK REFERENCE CHART: XTERRA
2009
Wheelarch Height (Unladen*1)
INFOID:0000000003303260
Unit: mm (in)
LEIA0085E
Engine type
VQ40DE
Drive type
2WD
Applied models
4WD
X and S
SE
X and S
O/R
SE
265/70R16
265/65R17
265/70R16
265/75R16
265/65R17
Front wheelarch height (Hf)
839 (33.03)
841 (33.11)
858 (33.78)
870 (34.25)
859 (33.82)
Rear wheelarch height (Hr)
872 (34.33)
872 (34.33)
892 (35.12)
904 (35.59)
892 (35.12)
Tire size
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Brake Specification
INFOID:0000000003303267
Unit: mm (in)
Front brake
Brake model Rotor outer diameter × thickness Pad Length × width × thickness
Rear brake
CLZ33VB 296 × 28 (11.654 × 1.102) 111.0 × 73.5 × 11.88 (4.73 × 2.894 × 0.468)
Cylinder bore diameter
51 (2.01)
Brake model
CLZ14VB
Rotor outer diameter × thickness Pad Length × width × thickness Cylinder bore diameter Control valve
Valve model
Brake booster
Booster model Diaphragm diameter
286 × 18.0 (11.260 × 0.709) 83.0 × 33.0 × 11.0 (3.268 × 1.299 × 0.433) 38.1 (1.50) Electric brake force distribution C215T 215 (8.46)
QUICK REFERENCE CHART: XTERRA
2009
Brake Pedal
INFOID:0000000003303268
Unit: mm (in)
WFIA0160E
Free height "H"
182.1 - 192.1 (7.17 - 7.56)
Depressed pedal height ("D" [under a force of 490 N (50 kg-f, 110 lb-f) with engine running]
105 - 115 (4.13 - 4.53)
Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch "C1" or “C2�
0.74 - 1.96 (0.029 - 0.077)
Pedal play "A"
3 - 11 (0.12 - 0.43)
Front Disc Brake
INFOID:0000000003303269
Unit: mm (in)
Brake model Brake pad
Disc rotor
CLZ33VB Standard thickness (new)
11.88 (0.468)
Repair limit thickness
2.0 (0.079)
Standard thickness (new)
28.0 (1.102)
Repair limit thickness
26.0 (1.024)
Maximum uneven wear (measured at 8 positions)
0.015 (0.0006)
Runout limit (with it attached to the vehicle)
0.05 (0.0020)
Rear Disc Brake Brake model Brake pad
Disc rotor
INFOID:0000000003303270
CLZ14VB Standard thickness (new)
11.0 mm (0.433 in)
Repair limit thickness
2.0 mm (0.079 in)
Standard thickness (new)
18.0 mm (0.709 in)
Repair limit thickness
16.0 mm (0.630 in)
Maximum uneven wear (measured at 8 positions)
0.015 mm (0.0006 in)
Runout limit (with it attached to the vehicle)
0.05 mm (0.0020 in)
QUICK REFERENCE CHART: XTERRA Fluids and Lubricants
2009 INFOID:0000000003303272
Capacity (Approximate)
Description
Metric
US measure
Imp measure
80
21 1/8 gal
17 5/8 gal
5.1
5 3/8 qt
4 1/2 qt
4.8
5 1/8 qt
4 1/4 qt
Dry engine (engine overhaul)
6.3
6 5/8 qt
5 1/2 qt
Cooling system (with reservoir at “MAX” level)
10.2
2 3/4 gal
2 1/4 gal
Automatic transmission fluid (ATF)
10.3
10 7/8 qt
9 1/8 qt
2WD
3.98
4 1/4 qt
3 1/2 qt
4WD
4.18
4 3/8 qt
3 5/8 qt
C200
1.6
3 3/8 pt
2 7/8 pt
M226
2.01
4 1/4 pt
3 1/2 pt
TX15B
2.0
2 1/8 qt
1 3/4 qt
R180A
0.85
1 3/4 pt
1 1/2 pt
1.0
2 1/8 pt
1 3/4 pt
Fuel Engine oil Drain and refill
With oil filter change Without oil filter change
Manual transmission (MT)
Rear final drive oil Transfer fluid Front final drive oil Power steering fluid (PSF) Brake and clutch fluid
—
—
—
Multi-purpose grease
—
—
—
1 1/4 gal
1 gal
1.54 ± 0.11 lb
1.54 ± 0.11 lb
6.1 fl oz
6.3 fl oz
Windshield washer fluid A/C system refrigerant A/C system oil
4.5 0.70 ± 0.05 kg 180 m
GENERAL INFORMATION
SECTION
GI
GENERAL INFORMATION
GI
B
C
D
E
CONTENTS Identification Number ...............................................21 Dimensions ..............................................................23 Wheels & Tires ........................................................23
F
PRECAUTION .............................................. 24
G
HOW TO USE THIS MANUAL ...................... 3 HOW TO USE THIS MANUAL ............................ 3 Description ................................................................ 3 Terms ........................................................................ 3 Units .......................................................................... 3 Contents .................................................................... 3 Component ................................................................ 3
PRECAUTIONS ................................................. 24 Description ...............................................................24 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................24 Precaution for NATS (NISSAN ANTI-THEFT SYSTEM) .................................................................24 General Precaution ..................................................25 Precaution for Three Way Catalyst ..........................26 Precaution for Fuel ..................................................26 Precaution for Multiport Fuel Injection System or Engine Control System ............................................26 Precaution for Hoses ...............................................26 Precaution for Engine Oils .......................................27 Precaution for Air Conditioning ................................28
HOW TO FOLLOW TROUBLE DIAGNOSES ..... 5 Description ................................................................ 5 How to Follow Test Groups in Trouble Diagnosis...... 5 Key to Symbols Signifying Measurements or Procedures ..................................................................... 6
HOW TO READ WIRING DIAGRAMS ................ 8 Connector symbols ................................................... 8 Sample/wiring diagram -example- ............................. 9 Description .............................................................. 10
ABBREVIATIONS ..............................................12 Abbreviation List ...................................................... 12
TIGHTENING TORQUE OF STANDARD BOLTS ................................................................13
I
J
K
L
LIFTING POINT ................................................. 29 Pantograph Jack ......................................................29 Garage Jack and Safety Stand ................................29 2-Pole Lift ................................................................29
M
TOW TRUCK TOWING ..................................... 31
N
Tightening Torque Table ......................................... 13
RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................14
H
Recommended Chemical Products and Sealants.... 14
Tow Truck Towing ...................................................31 Vehicle Recovery (Freeing a stuck vehicle) ............32
TERMINOLOGY .................................................15
BASIC INSPECTION ................................... 33
O
SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 33
P
ISO 15031-2 Terminology List ................................ 15
TIGHTENING TORQUE OF STANDARD BOLTS ................................................................19
Work Flow ................................................................33 Control Units and Electrical Parts ............................33 How to Check Terminal ...........................................34 Intermittent Incident .................................................37 Circuit Inspection .....................................................40
Tightening Torque Table ......................................... 19
FEATURES OF NEW MODEL ..................... 20 IDENTIFICATION INFORMATION .....................20 Model Variation ....................................................... 20
Revision: October 2008
CONSULT-III CHECKING SYSTEM ................. 45
GI-1
2009 Xterra
HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >
HOW TO USE THIS MANUAL
GI
HOW TO USE THIS MANUAL Description
INFOID:0000000004063511
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.
Terms
Units
INFOID:0000000004063513
• The UNITS given in this manual are primarily expressed as the SI UNIT (System International of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque.
D
E
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“Example” Range : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
I
Standard Drive Shaft Installation Bolt
J
: 44.3 N·m (4.5 kg-m, 33 ft-lb)
Contents
INFOID:0000000004063514
• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. • THE CONTENTS are listed on the first page of each section. • THE TITLE is indicated on the upper portion of each page and shows the part or system. • THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). • THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.
Component
K
L
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N
INFOID:0000000004063515
• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.
Revision: October 2008
C
INFOID:0000000004063512
• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value:Tolerance at inspection and adjustment. Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjustment.
Outer Socket Lock Nut
B
GI-3
2009 Xterra
O
P
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HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >
REH@1848D
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
1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease
2: Rubber grease
: Brake fluid
Refer to GI section for additional symbol definitions.
SYMBOLS
R@H@/ 638D
Revision: October 2008
GI-4
2009 Xterra
HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >
HOW TO FOLLOW TROUBLE DIAGNOSES
GI
Description
INFOID:0000000004063516
NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. • Before performing trouble diagnoses, read the “Work Flow” in each section. • After repairs, re-check that the problem has been completely eliminated. • Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. • When checking circuit continuity, ignition switch should be OFF. • Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. • Before checking voltage at connectors, check battery voltage. • After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.
How to Follow Test Groups in Trouble Diagnosis
B
C
D
E
F
INFOID:0000000004063517
G
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M
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I O@H@/ / 10F A
1. 2. 3. 4.
Test group number and test group title • Test group number and test group title are shown in the upper portion of each test group. Work and diagnosis procedure • Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and results • Questions and required results are indicated in test group. Action • Next action for each test group is indicated based on result of each question.
Revision: October 2008
GI-5
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2009 Xterra