2009 NISSAN XTERRA Service Repair Manual by 163215

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

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 vehicleâ&#x20AC;&#x2122;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

3,954 (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

Oil

Number of main bearings

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

244

240

−4

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

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

Nominal

13° 0′ (13.00°)

12° 45′ (12.75°)

Minimum

3.0 mm (0.12 in)

Nominal

4.0 mm (0.16 in)

Maximum

5.0 mm (0.20 in)

Minimum

0° 7′ (0.12°)

Nominal

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)

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

O/R

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)

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 â&#x20AC;&#x153;C2â&#x20AC;?

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

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

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

GENERAL INFORMATION

CONTENTS Identification Number ...............................................21 Dimensions ..............................................................23 Wheels & Tires ........................................................23

PRECAUTION .............................................. 24

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

LIFTING POINT ................................................. 29 Pantograph Jack ......................................................29 Garage Jack and Safety Stand ................................29 2-Pole Lift ................................................................29

TOW TRUCK TOWING ..................................... 31

Tightening Torque Table ......................................... 13

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................14

Recommended Chemical Products and Sealants.... 14

Tow Truck Towing ...................................................31 Vehicle Recovery (Freeing a stuck vehicle) ............32

TERMINOLOGY .................................................15

BASIC INSPECTION ................................... 33

SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 33

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

Description .............................................................. 45 Function and System Application ........................... 45

Revision: October 2008

GI-2

CONSULT-III Data Link Connector (DLC) Circuit ... 46 Wiring Diagram ....................................................... 47

2009 Xterra

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

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.

“Example” Range : 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Standard Drive Shaft Installation Bolt

: 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

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

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

GI-3

2009 Xterra

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

REH@1848D

Union bolt

Copper washer

Brake hose

Cap

Bleed valve

Sliding pin bolt

Piston seal

Piston

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

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

INFOID:0000000004063517

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

2009 Xterra

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

Key to Symbols Signifying Measurements or Procedures

INFOID:0000000004063518

R@H@0428D

Revision: October 2008

GI-6

2009 Xterra

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL > GI

N R@H@043/ D

Revision: October 2008

GI-7

2009 Xterra

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS Connector symbols

INFOID:0000000004063519

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”.

R@H@/ 146D

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

RF H252

Revision: October 2008

GI-8

2009 Xterra

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Sample/wiring diagram -example-

INFOID:0000000004063520

â&#x20AC;¢ For detail, refer to following GI-10, "Description". B

P I B@V @/ / / 4F A

Revision: October 2008

GI-9

2009 Xterra

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Description Number

INFOID:0000000004063521

Item

Description

Power supply

• This means the power supply of fusible link or fuse.

Fusible link

• “X” means the fusible link.

Number of fusible link/ fuse

• This means the number of fusible link or fuse location.

Fuse

• “/” means the fuse.

Current rating of fusible link/fuse

• This means the current rating of the fusible link or fuse.

Optional splice

• The open circle shows that the splice is optional depending on vehicle application.

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-56, "Electrical Units Location", PG-35, "Harness Layout".

Splice

• The shaded circle “

Page crossing

• This circuit continues to an adjacent page.

Option abbreviation

• This means the vehicle specifications which layouts the circuit between “

Relay

• This shows an internal representation of the relay.

Option description

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

Switch

• This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

Circuit (Wiring)

• This means the wiring.

System branch

• This shows that the circuit is branched to other systems.

Shielded line

• The line enclosed by broken line circle shows shield wire.

Component name

• This shows the name of a component.

Ground (GND)

• This shows the ground connection.

Connector

• This means the connector information. • This unit-side is described by the connector symbols.

Connectors

• This means that a transmission line bypasses two connectors or more.

” means the splice.

”.

• This shows a code for the color of the wire.

Wire color

BR = 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

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light 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 22

Terminal number

• This means the terminal number of a connector.

SWITCH POSITIONS Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:

Revision: October 2008

GI-10

2009 Xterra

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL > • ignition switch is “OFF”, • doors, hood and trunk lid/back door are closed, • pedals are not depressed, and • parking brake is released.

G RF H75/

MULTIPLE SWITCH The continuity of multiple switch is described in two ways as shown below. • The switch chart is used in schematic diagrams. • The switch diagram is used in wiring diagrams.

I R@H@/ / 06F A

Revision: October 2008

GI-11

2009 Xterra

ABBREVIATIONS < HOW TO USE THIS MANUAL >

ABBREVIATIONS Abbreviation List

INFOID:0000000004063522

The following ABBREVIATIONS are used: ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

AWD

All wheel drive

Drive range 1st gear

Drive range 2nd gear

Drive range 3rd gear

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

2nd range 2nd gear

2nd range 1st gear

1st range 2nd gear

1st range 1st gear

Revision: October 2008

GI-12

2009 Xterra

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS

Tightening Torque Table

Grade

Bolt size

Bolt diameter * mm

INFOID:0000000004063523

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

ft-lb

Hexagon flange bolt in-lb

6.0

8.0

M10

10.0

M12

12.0

1.25

4.6

—

M14

14.0

1.5

8.2

—

6.0

1.0

0.92

8.0

1.25

2.2

1.0

2.2

M10

10.0

1.5

1.25

M12

12.0

M14

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

0.71

1.25

13.5

1.4

—

1.7

—

1.0

13.5

1.4

—

1.7

—

1.5

2.9

—

3.6

—

1.25

2.9

—

3.6

—

1.75

4.6

—

5.6

—

6.6

—

100

—

1.1

—

2.9

—

2.9

—

4.6

—

5.6

—

4.6

—

5.6

—

1.75

8.2

—

100

—

1.25

8.2

—

100

—

14.0

1.5

130

—

170

125

—

6.0

1.0

1.1

—

13.5

1.4

—

8.0

1.25

2.9

—

3.6

—

1.0

2.9

—

3.6

—

M10

10.0

1.5

5.6

—

8.2

—

1.25

5.6

—

8.2

—

M12

12.0

1.75

100

—

130

—

1.25

100

—

130

—

M14

14.0

1.5

170

125

—

210

155

—

*: Nominal diameter

Special parts are excluded.

This standard is applicable to bolts having the following marks embossed on the bolt head.

P L F H/ 33@

Revision: October 2008

GI-13

2009 Xterra

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS < HOW TO USE THIS MANUAL >

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

INFOID:0000000004063524

Refer to the following chart for help in selecting the appropriate chemical product or sealant.

Aftermarket Crossreference Part Nos.

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

999MP-AM000P

99998-50505

Permatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P

99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) • Do not use on plastic.

999MP-AM002P

Permatex 56521

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194; Three Bond 1207,1215, 1216, 1217F, 1217G and 1217H Nissan RTV Part No. 999MP-A7007

999MP-AM003P (Ultra Grey)

Silicone RTV Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

Nissan Canada Part No. (Canada)

Purpose

Gasket Maker 4

Nissan North America Part No. (USA)

Product Description

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

Revision: October 2008

Threadlocker

Threadlocker (service tool removable)

–

999MP-AM004P

999MP-AM005P

GI-14

–

Three Bond 1281B or exact equivalent in its quality

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648

999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

2009 Xterra

TERMINOLOGY < HOW TO USE THIS MANUAL >

TERMINOLOGY

ISO 15031-2 Terminology List

INFOID:0000000004063525

All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart.

NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT-III

DLC for CONSULT-III

Diagnostic connector for CONSULT-III

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

Revision: October 2008

GI-15

2009 Xterra

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Exhaust gas recirculation temperature sensor EGR temperature sensor

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

Revision: October 2008

GI-16

2009 Xterra

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

Oxidation catalyst

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Revision: October 2008

GI-17

2009 Xterra

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

***: Not applicable

Revision: October 2008

GI-18

2009 Xterra

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS

Tightening Torque Table

Grade

Bolt size

Bolt diameter * mm

INFOID:0000000004063526

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

ft-lb

Hexagon flange bolt in-lb

6.0

8.0

M10

10.0

M12

12.0

1.25

4.6

—

M14

14.0

1.5

8.2

—

6.0

1.0

0.92

8.0

1.25

2.2

1.0

2.2

M10

10.0

1.5

1.25

M12

12.0

M14

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

0.71

1.25

13.5

1.4

—

1.7

—

1.0

13.5

1.4

—

1.7

—

1.5

2.9

—

3.6

—

1.25

2.9

—

3.6

—

1.75

4.6

—

5.6

—

6.6

—

100

—

1.1

—

2.9

—

2.9

—

4.6

—

5.6

—

4.6

—

5.6

—

1.75

8.2

—

100

—

1.25

8.2

—

100

—

14.0

1.5

130

—

170

125

—

6.0

1.0

1.1

—

13.5

1.4

—

8.0

1.25

2.9

—

3.6

—

1.0

2.9

—

3.6

—

M10

10.0

1.5

5.6

—

8.2

—

1.25

5.6

—

8.2

—

M12

12.0

1.75

100

—

130

—

1.25

100

—

130

—

M14

14.0

1.5

170

125

—

210

155

—

*: Nominal diameter

Special parts are excluded.

This standard is applicable to bolts having the following marks embossed on the bolt head.

P L F H/ 33@

Revision: October 2008

GI-19

2009 Xterra

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

FEATURES OF NEW MODEL IDENTIFICATION INFORMATION Model Variation Position

Character

INFOID:0000000004063527

Qualifier

Definition

Body type

T: Wagon

Engine

LK: VQ40DE

Axle

Drive

2 3

V: 2WD Z: 4WD Part time L: LH Q: X

R: S

Grade

U: Off Road T: SE

Transmission

N: 5-speed automatic transmission Y: 6-speed manual transmission

8 9

N54

Model

N54: Xterra

Intake

E: EGI

Zone

Equipment

A: Standard

Option Codes

N: Canada U: Federal

14 15 16

XXXXX

17 18 2WD Model

Body

Wagon

Engine

Transmission

Destination

RE5R05A (5A/T)

U.S.A.

VQ40DE FS6R31A (6M/T)

U.S.A.

Transmission

Destination

Grade

Model

TLKVLQN-EUA

TLKVLRN-EUA

TLKVLTN-EUA

TLKVLQY-EUA

TLKVLRY-EUA

Grade

Model

4WD Model

Body

Engine

Revision: October 2008

GI-20

2009 Xterra

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

U.S.A.

Wagon

VQ40DE

RE5R05A (5A/T)

Canada

U.S.A. Wagon

VQ40DE

FS6R31A (6M/T) Canada

TLKZLQN-EUA

TLKZLRN-EUA

O/R

TLKZLUN-EUA

TLKZLTN-EUA

TLKZLQN-ENA

TLKZLRN-ENA

O/R

TLKZLUN-ENA

TLKZLTN-ENA

TLKZLQY-EUA

TLKZLRY-EUA

O/R

TLKZLUY-EUA

TLKZLQY-ENA

TLKZLRY-ENA

O/R

TLKZLUY-ENA

Identification Number

INFOID:0000000004063528

L @V @H@/ / / 8YY

Emission control information label

Vehicle identification number 3. chassis number

Air conditioner specification label

Vehicle identification number plate

Tire placard

F.M.V.S.S./ C.M.V.S.S. certification label

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT Position

Character

Qualifier

Definition

1 2

5N1

Manufacturer

5N1: USA produced multi-purpose vehicle

Engine type

A: VQ40DE

Model code

N0: Model code N50, NISSAN Xterra

Body type

8: 4 Door wagon

3 4 5 6 7

Revision: October 2008

GI-21

2009 Xterra

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > Position

Character

Qualifier

Definition

Gross vehicle weight rating

Check digit

(0 to 9 or X) The code for the check digit is determined by a mathematical computation.

Model year

2009

Manufacturing plant

C: Smyrna Tennessee

Vehicle serial number

Chassis number

U: 2WD, 4-wheel ABS, Class D W: 4WD, 4-wheel ABS, Class D

12 13 14 15

XXXXXX

16 17

ENGINE SERIAL NUMBER

K@H@/ / 44D

TRANSFER SERIAL NUMBER

@F H0/ 7

AUTOMATIC TRANSMISSION NUMBER

O@H@/ / 43D

Revision: October 2008

GI-22

2009 Xterra

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > MANUAL TRANSMISSION NUMBER GI

Dimensions

INFOID:0000000004063529

C K@H@/ / 48D

D Unit: mm (in)

Drive type

2WD

4WD

Overall length

4539 (178.7)

Overall width

1849 (72.8)

Overall height (with roof rack)

1902 (74.9)

O/R

SE Front tread width

1570 (61.8)

Rear tread width

1570 (61.8)

Wheelbase

2700 (106.3)

Minimum Running Ground Clearance (with standard tires)

210.8 (8.3)

231.1 (9.1)

210.8 (8.3)

231.1 (9.1)

O/R

â&#x20AC;&#x201D;

241.3 (9.5)

210.8 (8.3)

231.1 (9.1)

Wheels & Tires Drive Type

All

INFOID:0000000004063530

Grade

Road wheel

Tire

Spare tire size

16 x 7JJ Steel

P265/70R16

16 X 7JJ Aluminum Alloy

P265/70R16

O/R

16 X 7JJ Aluminum Alloy

P265/75R16

17 X 7.5JJ Aluminum Alloy

P265/65R17

Revision: October 2008

GI-23

2009 Xterra

PRECAUTIONS < PRECAUTION >

PRECAUTION PRECAUTIONS Description

INFOID:0000000004063531

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

INFOID:0000000004063532

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SR and SB section of this Service Manual. WARNING: • To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. • Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SR section. • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

Precaution for NATS (NISSAN ANTI-THEFT SYSTEM)

INFOID:0000000004063533

NATS will immobilize the engine if someone tries to start it without the registered key of NATS. Both of the originally supplied ignition key IDs have been NATS registered. The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is functioning. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. • When NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position. This lighting up indicates that the anti-theft is not functioning, so prompt service is required. • When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs), CONSULT-III hardware and CONSULT-III NATS software is necessary. Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULT-III operation manual, NATS. Therefore, CONSULT-III NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. • When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS. • When failing to start the engine first time using the key of NATS, start as follows. 1. Leave the ignition key in "ON" position for approximately 5 seconds. 2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds. 3. Repeat step 1 and 2 again. 4. Restart the engine while keeping the key separate from any others on key-chain.

Revision: October 2008

GI-24

2009 Xterra

PRECAUTIONS < PRECAUTION >

General Precaution

INFOID:0000000004063535

• 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, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

D RF H174

• 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 transaxle/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.

RF H120

• 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.

K RDE178G

• 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. • Use approved bonding agent, sealants or their equivalents when required. Revision: October 2008

GI-25

O RF H122

2009 Xterra

PRECAUTIONS < PRECAUTION > • Use tools and recommended special tools where specified for safe and efficient service repairs. • When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. • Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

RF H123

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and TM sections.

Precaution for Three Way Catalyst

INFOID:0000000004063537

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. • Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. • When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. • Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precaution for Fuel

INFOID:0000000004063538

GASOLINE ENGINE Use unleaded gasoline with an octane rating of at least 87 AKI (91 RON). CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Precaution for Multiport Fuel Injection System or Engine Control System

INFOID:0000000004063539

• Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. • Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. • Be careful not to jar components such as ECM and mass air flow sensor. RF H676

Precaution for Hoses

INFOID:0000000004063540

HOSE REMOVAL AND INSTALLATION

Revision: October 2008

GI-26

2009 Xterra

PRECAUTIONS < PRECAUTION > • To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

C RL @/ 08C

• To reinstall the rubber hose securely, make sure that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

G RL @/ 1/ C

HOSE CLAMPING

• If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. • Discard old clamps; replace with new ones.

K RL @/ 10C

• After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

RL @/ 11C

Precaution for Engine Oils

INFOID:0000000004063541

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS • • • •

Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil.

Revision: October 2008

GI-27

2009 Xterra

PRECAUTIONS < PRECAUTION > • Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. • First aid treatment should be obtained immediately for open cuts and wounds. • Use barrier creams, applying them before each work period, to help the removal of oil from the skin. • Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. • Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. • If skin disorders develop, obtain medical advice without delay. • Where practical, degrease components prior to handling. • Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

Precaution for Air Conditioning

INFOID:0000000004063542

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.

Revision: October 2008

GI-28

2009 Xterra

LIFTING POINT < PRECAUTION >

LIFTING POINT

Pantograph Jack

INFOID:0000000004063543

K@H@/ / 3/ D

Garage Jack and Safety Stand

INFOID:0000000004063544

CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

@F H002

2-Pole Lift

INFOID:0000000004063545

WARNING: • When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced.

Revision: October 2008

GI-29

2009 Xterra

LIFTING POINT < PRECAUTION > â&#x20AC;¢ When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines.

V F H/ 14

Revision: October 2008

GI-30

2009 Xterra

TOW TRUCK TOWING < PRECAUTION >

TOW TRUCK TOWING

Tow Truck Towing

INFOID:0000000004491017

WARNING: • Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. • Place wheel chocks at both front and back of the wheels on the ground. CAUTION: • All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. • It is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. • Always attach safety chains before towing. • When towing, make sure that the transmission, steering system and powertrain are in good order. If any unit is damaged, dollies must be used. • Never tow an automatic transmission model with the rear wheels on the ground or four wheels on the ground (forward or backward) as this may cause serious and expensive damage to the transmission.

H V @H@/ / 2/ D

2WD MODEL

NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: • When towing with the front wheels on the ground: Turn the ignition key to the OFF position and move the transmission selector lever to N (neutral) position, turn the ignition key to OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism.

O V @H@/ / 20D

4WD MODEL

Revision: October 2008

GI-31

2009 Xterra

TOW TRUCK TOWING < PRECAUTION > NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: • Never tow 4WD models with any of the wheels on the ground as this may cause serious and expensive damage to the transfer case and transmission.

V @H@/ / 21D

Towing Point CAUTION: Never tow the vehicle using only the towing points. To avoid damaging the vehicle body, use proper towing equipment when towing.

K@H@/ / 42D

Vehicle Recovery (Freeing a stuck vehicle)

INFOID:0000000004491018

• Tow chains or cables must be attached only to the main structural members or tow hook (if equipped) of the vehicle. • Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems • Always pull the cable straight out from the front or rear of the vehicle. Never pull the vehicle at a sideways angle. • Pulling devices such as ropes or canvas straps are not recommended for use for vehicle towing or recovery.

Revision: October 2008

GI-32

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

BASIC INSPECTION

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Work Flow

INFOID:0000000004063548

WORK FLOW C

RF H727

STEP

DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

STEP 1

WHAT

Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

STEP 3

Get the proper diagnosis materials together including: • Power Supply Routing • System Operation Descriptions • Applicable Service Manual Sections • Check for any Service Bulletins Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

Control Units and Electrical Parts

INFOID:0000000004063549

PRECAUTIONS • • • •

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector.

Revision: October 2008

GI-33

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Do not apply excessive shock to the control unit by dropping or hitting it. • Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. • Be careful not to let oil to get on the control unit connector. • Avoid cleaning the control unit with volatile oil. • Do not disassemble the control unit, and do not remove the upper and lower covers. R@H@/ 144D

• When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. • When checking input and output signals of the control unit, use the specified check adapter.

RDE237M

How to Check Terminal

INFOID:0000000004063550

CONNECTOR AND TERMINAL PIN KIT • Use the connector and terminal pin kits listed below when replacing connectors or terminals. • The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

Revision: October 2008

GI-34

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Tool number (Kent-Moore No.) Tool name (J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) OBD-II Connector Kit Update

Description

E V @H@/ / / 3D

V @H@/ / / 4D

HOW TO PROBE CONNECTORS • Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. • The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip. Probing from Harness Side Standard type (not waterproof type) connector should be probed from harness side with “T” pin. • If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. • Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

K RF H730

Probing from Terminal Side FEMALE TERMINAL

• There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

RDK154U

Revision: October 2008

GI-35

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

RDK155U

MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin. CAUTION: Dot not bend terminal.

RDK156U

How to Check Enlarged Contact Spring of Terminal • An enlarged contact spring of a terminal may create intermittent signals in the circuit. • If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. NOTE: Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up.

RDK16/ U

While holding the wire of the male terminal, try to insert the male terminal into the female terminal. CAUTION: Do not force the male terminal into the female terminal with your hands.

RDK160U

Revision: October 2008

GI-36

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 4. While moving the connector, check whether the male terminal can be easily inserted or not.

C RDK161U

• If the male terminal can be easily inserted into the female terminal, replace the female terminal. E

G RDK162U

Waterproof Connector Inspection If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.

RUBBER SEAL INSPECTION

• Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. • The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

WIRE SEAL INSPECTION

• The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

L RDK164U

Terminal Lock Inspection Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

RDK22/ U

Intermittent Incident

INFOID:0000000004063551

DESCRIPTION Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-

Revision: October 2008

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2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics:

• Vehicle vibration • Heat sensitive • Freezing • Water intrusion • Electrical load • Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. Connector & Harness Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. Hint Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. Sensor & Relay Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

RF H728

Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: • Connectors not fully seated. • Wiring harness not long enough and is being stressed due to engine vibrations or rocking. • Wires laying across brackets or moving components. • Loose, dirty or corroded ground wires. • Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. Behind the Instrument Panel An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw. Under Seating Areas

Revision: October 2008

GI-38

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or GI pinching.

HEAT SENSITIVE

• The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. • To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. CAUTION: Do not heat components above 60°C (140°). • If incident occurs while heating the unit, either replace or properly insulate the component.

RF H731

FREEZING • The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. • There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. • The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

RF H732

WATER INTRUSION The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. CAUTION: Do not spray water directly on any electrical components.

RF H733

ELECTRICAL LOAD The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

P RF H734

COLD OR HOT START UP On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. Revision: October 2008

GI-39

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

Circuit Inspection

INFOID:0000000004063552

DESCRIPTION • In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. • You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN

A circuit is open when there is no continuity through a section of the circuit. There are two types of shorts.

SHORT

• SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

• SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to GI-34, "How to Check Terminal" to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUIT Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

RF H735,@

Continuity Check Method The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic. • Disconnect the battery negative cable. • Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) • Connect one probe of the DMM to the fuse block terminal on the load side. • Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) • Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) • Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example. Voltage Check Method To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. • Connect one probe of the DMM to a known good ground. • Begin probing at one end of the circuit and work your way to the other end. • With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. Revision: October 2008

GI-40

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > no voltage; open is between fuse block and SW1 (point A). • Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). • Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system, please refer to the following schematic.

F RF H736,@

Resistance Check Method • Disconnect the battery negative cable and remove the blown fuse. • Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. • With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. • Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. • Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. Voltage Check Method • Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). • With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. • With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. • With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION • Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. • Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. Revision: October 2008

GI-41

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • When inspecting a ground connection follow these rules: - Remove the ground bolt or screw. - Inspect all mating surfaces for tarnish, dirt, rust, etc. - Clean as required to assure good contact. - Reinstall bolt or screw securely. - Inspect for “add-on” accessories which may be interfering with the ground circuit. - If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. • For detailed ground distribution information, refer to “Ground Distribution” in PG section.

RF H742

VOLTAGE DROP TESTS • Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. • Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. • Unwanted resistance can be caused by many situations as follows: - Undersized wiring (single strand example) - Corrosion on switch contacts - Loose wire connections or splices. • If repairs are needed always use wire that is of the same or larger gauge. Measuring Voltage Drop — Accumulated Method • Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. • Operate the circuit. • The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

Revision: October 2008

GI-42

2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. GI

RF H863

Measuring Voltage Drop — Steb-by-Step • The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). • Circuits in the “Computer Controlled System” operate on very low amperage. • The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. • The step by step voltage drop test can identify a component or wire with too much resistance.

M R@H@/ 147D

CONTROL UNIT CIRCUIT TEST System Description • When the switch is ON, the control unit lights up the lamp.

CASE 1

L F H/ 23@

Revision: October 2008

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2009 Xterra

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Body ground

Switch

Body ground

Lamp

Value (Approx.)

In case of high resistance such as single strand (V) *

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Switch ON

Battery voltage

Switch OFF

Condition

Input/ Output Input

Output

Approx. 0 Approx. 0 (Inoperative lamp) Approx. 0

• The voltage value is based on the body ground. • *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

CASE 2

L F H/ 24@

INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Condition

Input/ Output

Body ground

Lamp

Output

Body ground

Switch

Input

Value (Approx.)

In case of high resistance such as single strand (V) *

Switch ON

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Switch ON

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Battery voltage

• The voltage value is based on the body ground. • *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

Revision: October 2008

GI-44

2009 Xterra

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III CHECKING SYSTEM

Description

INFOID:0000000004063553

• When CONSULT-III is connected with a data link 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. 1

: Hood release handle

: Data link connector

• Refer to “CONSULT-III Operation Manual” for more information. @KAH@/ / 36YY

Function and System Application

INFOID:0000000004063554

IPDM E/R

BCM

METER/M&A

DIFF LOCK*1

ALL MODE AWD/4WD*2

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-III.

Self-diagnostic

Self-diagnostic can be performed quickly.

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

Data monitor

Input/Output data in the ECM can be read.

CAN diagnosis

The condition of CAN communication can be indicated by a topology.

CAN diagnosis support monitor

The communication condition of CAN communication line can be read.

Active test

Diagnostic Test Mode in which CONSULT-III drives some actuators apart from the ECMs and also shifts some parameters in a specified range.

Function test

This mode can show results of self-diagnosis of ECU with either “OK” or “NG”. For engines, more practical tests regarding sensors/switches and/or actuators are available.

DTC & SRT confirmation

The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed.

DTC work support

The operating condition to confirm Diagnosis Trouble Codes can be selected.

ECM/ECU part number

ECM/ECU part number can be read.

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

Passenger Airbag

Displays the STATUS (readiness) of the front passenger air bag.

Configuration

Sets control module parameters to match vehicle options.

Revision: October 2008

Function

GI-45

AIR BAG

ABS

Work support

Diagnostic test mode

ENGINE

TRANSMISSION

2009 Xterra

CONSULT-III CHECKING SYSTEM

ENGINE

TRANSMISSION

ABS

AIR BAG

IPDM E/R

BCM

METER/M&A

DIFF LOCK*1

ALL MODE AWD/4WD*2

< BASIC INSPECTION >

PIN read*3

This mode shows the BCM-specific 5-digit code.

Control unit initialization*3

All registered ignition key IDs in NATS components can be initialized and new IDs can be registered.

Diagnostic test mode

Function

x : Applicable *1: With differential lock *2: With 4-wheel drive *3: With security card installed

CONSULT-III Data Link Connector (DLC) Circuit

INFOID:0000000004063555

INSPECTION PROCEDURE If the CONSULT-III cannot diagnose the system properly, check the following items. Symptom

Check item

CONSULT-III cannot access any system.

• CONSULT-III DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4)

CONSULT-III cannot access individual system. (Other systems can be accessed.)

• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit between the system and CONSULT-III DLC (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit CAN communication line. Refer to LAN-14, "Trouble Diagnosis Flow Chart".

NOTE: The CAN and DDL2 circuits from DLC pins 6, 7 and 14 may be connected to more than one system. A short in any circuit connected to a control unit in one system may affect CONSULT-III access to other systems.

Revision: October 2008

GI-46

2009 Xterra

CONSULT-III CHECKING SYSTEM < BASIC INSPECTION >

Wiring Diagram

INFOID:0000000004063556

P @A@V @/ / 00F A

Revision: October 2008

GI-47

2009 Xterra

ENGINE

SECTION

ENGINE MECHANICAL

CONTENTS VQ40DE

Removal and Installation .........................................14

PRECAUTION ............................................... 3

SPARK PLUG ................................................... 15 Exploded View .........................................................15 Removal and Installation .........................................15

PRECAUTIONS ................................................... 3 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 3 Precaution for Drain Engine Coolant ......................... 3 Precaution for Disconnecting Fuel Piping ................. 3 Precaution for Removal and Disassembly ................ 3 Precaution for Inspection, Repair and Replacement .......................................................................... 3 Precaution for Assembly and Installation .................. 3 Parts Requiring Angle Tightening ............................. 4 Precaution for Liquid Gasket ..................................... 4

PREPARATION ............................................ 6 PREPARATION ................................................... 6 Special Service Tool ................................................. 6 Commercial Service Tool .......................................... 8

FUNCTION DIAGNOSIS .............................. 10 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................10 NVH Troubleshooting - Engine Noise ..................... 10 Use the Chart Below to Help You Find the Cause of the Symptom ....................................................... 10

Valve Clearance ......................................................17 Compression Pressure ............................................21

ON-VEHICLE REPAIR ................................. 23 ENGINE ROOM COVER ................................... 23 Removal and Installation .........................................23

AIR CLEANER AND AIR DUCT ....................... 24 Exploded View .........................................................24 Removal and Installation .........................................24

INTAKE MANIFOLD COLLECTOR .................. 25 Exploded View .........................................................25 Removal and Installation .........................................25

INTAKE MANIFOLD ......................................... 28

Exploded View .........................................................28 Removal and Installation .........................................28

EXHAUST MANIFOLD AND THREE WAY CATALYST ........................................................ 30

DRIVE BELTS ....................................................12

OIL PAN AND OIL STRAINER ......................... 34

Exploded View ........................................................ 12 Checking Drive Belts ............................................... 12 Adjustment .............................................................. 12 Removal and Installation ......................................... 12 Drive Belt Auto Tensioner and Idler Pulley ............. 13

Exploded View .........................................................34 Removal and Installation .........................................34

Revision: October 2008

COMPRESSION PRESSURE ........................... 21

Exploded View .........................................................30 Removal and Installation .........................................30

Exploded View ........................................................ 14

CAMSHAFT VALVE CLEARANCE .................. 17

ON-VEHICLE MAINTENANCE .................... 12

AIR CLEANER FILTER ......................................14

IGNITION COIL ................................................. 39 Exploded View .........................................................39 Removal and Installation .........................................39

ROCKER COVER ............................................. 40

EM-1

2009 Xterra

Exploded View ........................................................ 40 Removal and Installation ........................................ 40

Disassembly and Assembly .................................... 95 Inspection After Disassembly .................................. 97

FUEL INJECTOR AND FUEL TUBE ................. 44

REMOVAL AND INSTALLATION ............. 102

Exploded View ........................................................ 44 Removal and Installation ........................................ 44

ENGINE ASSEMBLY ....................................... 102

FRONT TIMING CHAIN CASE .......................... 49

Exploded View ...................................................... 102 Removal and Installation ....................................... 102

Exploded View ........................................................ 49 Removal and Installation ........................................ 50

DISASSEMBLY AND ASSEMBLY ........... 106

TIMING CHAIN .................................................. 59

ENGINE UNIT ................................................... 106

Exploded View ........................................................ 59 Removal and Installation ........................................ 60

Exploded View ...................................................... 106 Disassembly and Assembly .................................. 107 Inspection After Disassembly ................................ 117 Dowel Pin Alignment ............................................. 127

CAMSHAFT ....................................................... 79 Exploded View ........................................................ 79 Removal and Installation ........................................ 80

OIL SEAL ........................................................... 88 Removal and Installation of Valve Oil Seal ............. 88 Removal and Installation of Front Oil Seal ............. 88 Removal and Installation of Rear Oil Seal .............. 89

CYLINDER HEAD .............................................. 91 Exploded View ........................................................ 91 Removal and Installation ........................................ 91 Exploded View ........................................................ 95

Revision: October 2008

HOW TO SELECT PISTON AND BEARING .. 129 How to Select Piston and Bearing ........................ 129

SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... 134 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................ 134 Standard and Limit ................................................ 134

EM-2

2009 Xterra

PRECAUTIONS [VQ40DE]

< PRECAUTION >

PRECAUTION

PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

INFOID:0000000004063557

Precaution for Drain Engine Coolant

INFOID:0000000004063558

Drain engine coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping

INFOID:0000000004063559

• Before starting work, make sure no fire or spark producing items are in the work area. • Release fuel pressure before disconnecting and disassembly. • After disconnecting pipes, plug openings to stop fuel leakage.

Precaution for Removal and Disassembly

J INFOID:0000000004063560

• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. • Exercise maximum care to avoid damage to mating or sliding surfaces. • Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials. • Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. • When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Precaution for Inspection, Repair and Replacement

INFOID:0000000004063561

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

Precaution for Assembly and Installation

O INFOID:0000000004063562

• Use torque wrench to tighten bolts or nuts to specification. • When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. • Replace with new gasket, packing, oil seal or O-ring. • Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage. • Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Revision: October 2008

EM-3

2009 Xterra

PRECAUTIONS [VQ40DE] < PRECAUTION > • Release air within route when refilling after draining engine coolant. • Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections. • After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gasses for leakage.

Parts Requiring Angle Tightening

INFOID:0000000004063563

• For the final tightening of the following engine parts use Tool: Tool number

: KV10112100 (BT-8653-A)

Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tightening) • Do not use a torque value for final tightening. • The torque value for these parts are for a preliminary step. • Ensure thread and seat surfaces are clean and coated with engine oil.

Precaution for Liquid Gasket

INFOID:0000000004063564

REMOVAL OF LIQUID GASKET SEALING • After removing nuts and bolts, separate the mating surface and remove old liquid gasket sealing using Tool. Tool number

: KV10111100 (J-37228)

CAUTION: Be careful not to damage the mating surfaces. • Tap seal cutter to insert it (1), and then slide it by tapping on the side (2) as shown. • In areas where Tool is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces.

V AH@/ 455D

LIQUID GASKET APPLICATION PROCEDURE 1.

Remove the old liquid gasket adhering to the gasket application surface and the mating surface using suitable tool. • Remove liquid gasket completely from the groove of the gasket application surface, bolts, and bolt holes. Thoroughly clean the mating surfaces and remove adhering moisture, grease and foreign materials.

OAHB/ / / 2D

Revision: October 2008

EM-4

2009 Xterra

PRECAUTIONS [VQ40DE]

< PRECAUTION > 3. Attach liquid gasket tube to the Tool.

Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". Apply the liquid gasket without breaks to the specified location with the specified dimensions.

C V AH@/ 456D

• If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. • As for bolt holes, normally apply the liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. • Within five minutes of liquid gasket application, install the mating component. • If the liquid gasket protrudes, wipe it off immediately. • Do not retighten nuts or bolts after the installation. • Wait 30 minutes or more after installation, before refilling the engine with engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them.

G RDL 048E

Revision: October 2008

EM-5

2009 Xterra

PREPARATION [VQ40DE]

< PREPARATION >

PREPARATION PREPARATION Special Service Tool

INFOID:0000000004063565

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description

ST0501S000 ( — ) Engine stand assembly 1. ST05011000 ( — ) Engine stand 2. ST05012000 ( — ) Base

Disassembling and assembling engine

MS/ 31

Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

— (J-45488) Quick connector release

OAHB/ 087D

Removing oil pan (lower and upper), front and rear timing chain case, etc.

KV10111100 (J-37228) Seal cutter

MS/ 35

Pressing the tube of liquid gasket

WS39930000 ( — ) Tube presser

MS/ 41

Loosening or tightening air fuel ratio A/F sensor a: 22 mm (0.87 in)

KV991J0050 (J-44626) Air fuel sensor Socket

KAH@/ 333D

Loosening or tightening heated oxygen sensor 1 a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

MS525

Revision: October 2008

EM-6

2009 Xterra

PREPARATION [VQ40DE]

< PREPARATION > Tool number (Kent-Moore No.) Tool name

Description

KV10116200 (J-26336-B) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2.KV10109220 ( â&#x20AC;&#x201D; ) Adapter

Disassembling valve mechanism Part (1) is a component of KV10116200 (J26336-B), but Part (2) is not so.

C OAHB054/ D

Replacing valve oil seal

KV10107902 (J-38959) Valve oil seal puller

MS/ 00

Installing valve oil seal

â&#x20AC;&#x201D; (J-39386) Valve oil seal drift

H MS/ 13

Installing piston assembly into cylinder bore

EM03470000 (J-8037) Piston ring compressor

MS/ 33

Tightening bolts for bearing cap, cylinder head, etc. in angle

KV10112100 (BT-8653-A) Angle wrench

M MS/ 03

Removing pilot converter

ST16610001 (J-23907) Pilot bushing puller

O MS/ 34

Revision: October 2008

EM-7

2009 Xterra

PREPARATION [VQ40DE]

< PREPARATION > Tool number (Kent-Moore No.) Tool name

Description

KV991J0120 (J-47128) Seal installer

Installing rear main seal

KAH@/ 341D

Removing and installing crankshaft pulley

— (J-48761) Ring gear stopper

@KAH@/ 412YY

Commercial Service Tool

INFOID:0000000004063566

Tool number (Kent-Moore No.) Tool name

Description

( — ) Power tool

Loosening nuts and bolts

OAHB/ 08/ D

Removing and installing flywheel Size: T55

KV991J0100 (J-46531) TORX socket

OAHB0002D

( — ) Spark plug wrench

Removing and installing spark plug

MS/ 36

(J-24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with angle wrench [SST: KV10112100 (BT8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) MS472

Revision: October 2008

EM-8

2009 Xterra

PREPARATION [VQ40DE]

< PREPARATION > Tool number (Kent-Moore No.) Tool name

Description

( — ) Valve seat cutter set

Finishing valve seat dimensions

C MS/ 37

( — ) Piston ring expander

Removing and installing piston ring

MS/ 2/

( — ) Valve guide drift

Removing and installing valve guide Intake and Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.

H MS/ 04

( — ) Valve guide reamer

(1): Reaming valve guide inner hole (2): Reaming hole for oversize valve guide Intake and Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.175 - 10.196 mm (0.4006 - 0.4014 in) dia. MS/ 05

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor b: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor

(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner

@DL 377

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

( — ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

O @DL 378

( — ) Manual lift table caddy

Removing and installing engine

YY@010/ C

Revision: October 2008

EM-9

2009 Xterra

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [VQ40DE]

< FUNCTION DIAGNOSIS >

FUNCTION DIAGNOSIS NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting - Engine Noise

INFOID:0000000004063567

OAHB1762D

Use the Chart Below to Help You Find the Cause of the Symptom 1.

INFOID:0000000004063568

Locate the area where noise occurs.

Revision: October 2008

EM-10

2009 Xterra

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [VQ40DE]

< FUNCTION DIAGNOSIS > 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.

Operating condition of engine Location of noise

Type of noise

Top of engine Rocker cover Cylinder head

Front of engine Timing chain case

When starting

When idling

When racing

While driving

Ticking or clicking

—

Tappet noise

Valve clearance

EM-17

Rattle

—

Camshaft bearing noise

Camshaft runout Camshaft journal oil clearance

EM-80 EM-80

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-117 EM-117

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-117 EM-117 EM-117 EM-117

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-117 EM-117

Slap or rap

—

Check item

Knock

Connecting rod bearing noise

Knock

—

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-117 EM-117

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-60 EM-60

Drive belts (Sticking or slipping)

Drive belts deflection

Idler pulley bearing operation

Tapping or ticking

Squeaking or fizzing Front of engine

Reference page

After warmup

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Source of noise

Before warmup

—

L EM-12

Creaking

Drive belts (Slipping)

Squall Creak

—

Water pump noise

Water pump operation

CO-21

Rattle

—

VTC

VTC lock pin clearance

EM-60

A: Closely related B: Related

C: Sometimes related

—: Not related

Revision: October 2008

EM-11

2009 Xterra

DRIVE BELTS [VQ40DE]

< ON-VEHICLE MAINTENANCE >

ON-VEHICLE MAINTENANCE DRIVE BELTS Exploded View

INFOID:0000000004063569

KAH@/ 316D

Drive belt

Power steering oil pump pulley

Generator pulley

Crankshaft pulley

A/C compressor

Cooling fan pulley

Idler pulley

Drive belt tensioner

Checking Drive Belts

INFOID:0000000004063570

WARNING: Be sure to perform when the engine is stopped. 1. Remove air duct and resonator assembly when inspecting drive belt. Refer to EM-24, "Removal and Installation". 2. Make sure that the auto tensioner indicator is within the allowable working range (A) as shown. 3. Visually check entire belt for wear, damage or cracks. 4. If the indicator is out of allowable working range or drive belt is damaged, replace the drive belt. Refer to EM-12, "Removal and Installation".

@V AH@/ 612YY

Adjustment

INFOID:0000000004063571

There is no manual drive belt tension adjustment. The drive belt tension is automatically adjusted by the drive belt auto tensioner.

Removal and Installation

INFOID:0000000004063572

REMOVAL 1.

Remove air duct and resonator assembly. Refer to EM-24, "Removal and Installation".

Revision: October 2008

EM-12

2009 Xterra

DRIVE BELTS < ON-VEHICLE MAINTENANCE > 2. Rotate the drive belt auto tensioner in the direction of arrow (loosening direction of tensioner) as shown, using suitable tool. WARNING: Avoid placing hand in a location where pinching may occur if the tool accidentally comes off. 3. Remove the drive belt.

[VQ40DE] A

C KAH@/ 317D

INSTALLATION Installation is in the reverse order of removal. CAUTION: Make sure belt is securely installed around all pulleys.

Drive Belt Auto Tensioner and Idler Pulley

INFOID:0000000004063573

KAH@/ 318D

Idler pulley

Drive belt auto tensioner

REMOVAL 1. 2. 3. 4.

Remove air duct and resonator assembly. Refer to EM-24, "Removal and Installation". Remove drive belt. Refer to EM-12, "Removal and Installation". Remove engine cooling fan assembly (motor driven type). Refer to CO-19, "Removal and Installation (Motor driven type)". Remove auto tensioner and idler pulley using power tool.

INSTALLATION Installation is in the reverse order of removal.

Revision: October 2008

EM-13

2009 Xterra

AIR CLEANER FILTER [VQ40DE]

< ON-VEHICLE MAINTENANCE >

AIR CLEANER FILTER Exploded View

INFOID:0000000004063574

@V AH@/ 022F A

Air cleaner case (lower)

Air duct and resonator

Air cleaner filter

Air cleaner case (upper)

Front

Removal and Installation

INFOID:0000000004063575

REMOVAL 1. 2.

Unhook clips, and lift air cleaner case (upper). Remove air cleaner filter.

INSTALLATION Installation is in the reverse order of removal.

Revision: October 2008

EM-14

2009 Xterra

SPARK PLUG [VQ40DE]

< ON-VEHICLE MAINTENANCE >

SPARK PLUG

Exploded View

INFOID:0000000004063576

G OAHB18/ 0D

Ignition coil

Spark plug

Removal and Installation

INFOID:0000000004063577

REMOVAL

1. 2. 3.

Remove the engine room cover using power tool. Refer to EM-23, "Removal and Installation". Remove the ignition coil. Refer to EM-39, "Removal and Installation". Remove the spark plug using a suitable tool. CAUTION: Do not drop or shock it.

RDL 183@

INSPECTION AFTER REMOVAL • Do not use a wire brush for cleaning.

RL @662B

• If the spark plug tip is covered with carbon, spark plug cleaner may be used.

Revision: October 2008

EM-15

2009 Xterra

SPARK PLUG [VQ40DE]

< ON-VEHICLE MAINTENANCE > Cleaner air pressure Cleaning time

: Less than 588 kPa (5.9 bar, 6 kg/cm2, 85 psi) : Less than 20 seconds

â&#x20AC;¢ Checking and adjusting spark plug gap is not required between change intervals.

RL @7/ 5B@

INSTALLATION Installation is in the reverse order of removal. CAUTION: Do not drop or shock the spark plug. Make

NGK

Standard type

DILFR5A-11

Gap (nominal)

1.1 mm (0.043 in)

Revision: October 2008

EM-16

2009 Xterra

CAMSHAFT VALVE CLEARANCE [VQ40DE]

< ON-VEHICLE MAINTENANCE >

CAMSHAFT VALVE CLEARANCE

Valve Clearance

INFOID:0000000004063578

INSPECTION

NOTE: Perform the following inspection after removal, installation or replacement of camshaft or valve-related parts, or if there are unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise). 1. Remove the engine room cover. Refer to EM-23, "Removal and Installation". 2. Remove the air cleaner and air duct assembly. Refer to EM-24, "Exploded View". 3. Remove rocker covers (RH and LH banks). Refer to EM-40, "Removal and Installation". 4. Measure the valve clearance as follows: a. Set No. 1 cylinder at TDC of its compression stroke. • Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).

H @V AH@/ 608YY

• Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of RH bank) are located as shown. • If not, rotate crankshaft one revolution (360°) and align as shown.

RDL 307F

Use feeler gauge, measure the clearance between valve lifter and camshaft.

O RDL 028C

Valve clearance: Unit: mm (in)

Cold

Hot * (reference data)

Intake

0.26 - 0.34 (0.010 - 0.013)

0.304 - 0.416 (0.012 - 0.016)

Exhaust

0.29 - 0.37 (0.011 - 0.015)

0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)

Revision: October 2008

EM-17

2009 Xterra

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > • Measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the illustration) with feeler gauge. • No. 1 cylinder at compression TDC Measuring position (RH bank) No. 1 cylinder at compression TDC

INT

No. 3 CYL.

No. 5 CYL.

EXH

Measuring position (LH bank) No. 1 cylinder at compression TDC

No. 1 CYL. × No. 2 CYL.

No. 4 CYL.

No. 6 CYL. ×

INT EXH

[VQ40DE]

OAHB1/ 43D

Rotate crankshaft by 240° clockwise (when viewed from engine front) to align No. 3 cylinder at TDC of its compression stroke. NOTE: Crankshaft pulley bolt flange has a stamped line every 60°. They can be used as a guide to rotation angle.

OAHB1805D

• Measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the illustration) with feeler gauge. • No. 3 cylinder at compression TDC Measuring position (RH bank) No. 3 cylinder at compression TDC

No. 3 CYL.

No. 5 CYL. ×

INT

Measuring position (LH bank) No. 3 cylinder at compression TDC

No. 1 CYL.

EXH

INT EXH

No. 2 CYL.

No. 4 CYL.

No. 6 CYL.

× ×

OAHB1/ 44D

Revision: October 2008

EM-18

2009 Xterra

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > d. Rotate crankshaft by 240° clockwise (when viewed from engine front) to align No. 5 cylinder at TDC of compression stroke.

[VQ40DE] A

C OAHB1805D

• Measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the illustration) with feeler gauge. • No. 5 cylinder at compression TDC Measuring position (RH bank) No. 5 cylinder at compression TDC

EXH

No. 3 CYL.

No. 5 CYL.

INT

× ×

INT

Measuring position (LH bank) No. 5 cylinder at compression TDC

No. 1 CYL.

No. 2 CYL.

No. 4 CYL.

No. 6 CYL.

× ×

EXH

OAHB1/ 45D

For the measured value out of the standard, perform adjustment.

ADJUSTMENT

• Perform adjustment depending on selected head thickness of valve lifter. 1. Measure the valve clearance. 2. Remove camshaft. Refer to EM-80, "Removal and Installation". 3. Remove valve lifters at the locations that are out of the standard. 4. Measure the center thickness of removed valve lifters with micrometer.

P J AH@/ / 46D

Use the equation below to calculate valve lifter thickness for replacement.

Revision: October 2008

EM-19

2009 Xterra

CAMSHAFT VALVE CLEARANCE [VQ40DE]

< ON-VEHICLE MAINTENANCE > Valve lifter thickness calculation: t = t1+ (C1– C2) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1 C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0.30 mm (0.012 in)* Exhaust : 0.33 mm (0.013 in)* *: Approximately 20°C (68°F) • Thickness of new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder).

J AH@/ 008D

Intake

Stamp mark

Thickness

788U

7.88 mm (0.3102 in)

790U

7.90 mm (0.3110 in)

840U

8.40 mm (0.3307 in)

Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-134, "Standard and Limit". Exhaust

Stamp mark

Thickness

N788

7.88 mm (0.3102 in)

N790

7.90 mm (0.3110 in)

N836

8.36 mm (0.3291 in)

Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-134, "Standard and Limit". CAUTION: Install identification letter at the end and top, “U” and “N”, at each of proper positions. (Be careful of mis-installation between intake and exhaust.) 6. Install selected valve lifter. 7. Install camshaft. Refer to EM-80, "Removal and Installation". 8. Manually turn crankshaft pulley a few turns. 9. Make sure that the valve clearances for cold engine are within the specifications by referring to the specified values. 10. Installation of the remaining components is in the reverse order of removal. 11. Start the engine, and check for unusual noise and vibration.

Revision: October 2008

EM-20

2009 Xterra

COMPRESSION PRESSURE [VQ40DE]

< ON-VEHICLE MAINTENANCE >

COMPRESSION PRESSURE

Compression Pressure

INFOID:0000000004063579

CHECKING COMPRESSION PRESSURE 1. 2. 3.

Warm up engine thoroughly. Release fuel pressure. Refer to EC-487, "Fuel Pressure Check". Disconnect fuel pump fuse to avoid fuel injection during measurement.

AAH@/ 423D

4. 5. 6. 7.

Remove intake manifold collector. Refer to EM-25, "Removal and Installation". Remove spark plug from each cylinder. Refer to EM-15, "Removal and Installation". Connect engine tachometer (not required in use of CONSULT-III). Install compression tester with adapter onto spark plug hole.

OAHB/ 8/ / D

• Use compression gauge whose pick up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.

N RAH@/ 422D

Turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cylinder. Compression pressure: Unit: kPa (kg/cm2, psi) /rpm

Standard

Minimum

Differential limit between cylinders

1,275 (13.0, 185) / 300

981 (10.0, 142) / 300

98 (1.0, 14) / 300

CAUTION: Always use a fully charged battery to obtain specified engine speed. • If the engine speed is out of the specified range, check the battery liquid for proper gravity. Check the engine speed again with normal battery gravity. Revision: October 2008

EM-21

2009 Xterra

COMPRESSION PRESSURE [VQ40DE] < ON-VEHICLE MAINTENANCE > • If the compression pressure is below the minimum value, check the valve clearances and parts associated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again. • If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. • If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the piston rings and replace if necessary. • If the compression pressure remains at low level despite the addition of engine oil, the valves may be malfunctioning. Check the valves for damage. Replace the 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, cylinder head gaskets may be leaking, or a valve in adjacent cylinders may be damaged. Inspect and repair as required. 9. Install the components in the reverse order of removal. 10. Start the engine, and confirm that it runs smoothly. 11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-78, "Description".

Revision: October 2008

EM-22

2009 Xterra

ENGINE ROOM COVER [VQ40DE]

< ON-VEHICLE REPAIR >

ON-VEHICLE REPAIR

ENGINE ROOM COVER Removal and Installation

INFOID:0000000004063580

CAUTION: Do not damage or scratch cover when installing or removing.

REMOVAL 1. 2.

Remove the engine room cover bolts using power tool. Lift up on engine room cover firmly to dislodge snap fit mounts.

F V AH@/ 511D

INSTALLATION Installation is in the reverse order of removal.

Revision: October 2008

EM-23

2009 Xterra

AIR CLEANER AND AIR DUCT [VQ40DE]

< ON-VEHICLE REPAIR >

AIR CLEANER AND AIR DUCT Exploded View

INFOID:0000000004063581

@V AH@/ 022F A

Air cleaner case (lower)

Air duct and resonator assembly

Air cleaner filter

Air cleaner case (upper)

Front

Removal and Installation

INFOID:0000000004063582

CAUTION: Handle mass air flow sensor with care. • Do not shock it. • Do not disassemble it. • Do not touch its sensor. NOTE: Add marks as necessary for easier installation.

REMOVAL 1. 2. 3. 4.

Remove the engine room cover using power tool. Refer to EM-23, "Removal and Installation". Disconnect the harness connector from air cleaner case (upper). Remove the air duct and resonator assembly and air cleaner case (upper). Remove air cleaner filter and air cleaner case (lower).

INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for cracks or tears. • If anything found, replace air duct and resonator assembly.

INSTALLATION Installation is in the reverse order of removal.

Revision: October 2008

EM-24

2009 Xterra

INTAKE MANIFOLD COLLECTOR [VQ40DE]

< ON-VEHICLE REPAIR >

INTAKE MANIFOLD COLLECTOR

Exploded View

INFOID:0000000004063583

I V AH@/ 620D

Vacuum tank

VIAS control solenoid valve

Vacuum hose

Intake manifold collector support

Water hose

Electronic throttle control actuator

Water hose

EVAP hose

Bracket

10. EVAP hose

11. EVAP canister purge volume control solenoid valve

12. Gasket

13. Gasket

14. Intake manifold collector

15. Clip

16. PCV hose

17. Connector

18. PCV hose

To intake manifold collector

To cylinder head (RH bank)

To power valve

Removal and Installation

To throttle body

INFOID:0000000004063584

REMOVAL 1. 2. 3. 4. a.

Remove the engine undercover using power tool. Remove engine room cover using power tool. Refer to EM-23, "Removal and Installation". Remove air cleaner case (upper) and air duct and resonator assembly. Refer to EM-24, "Removal and Installation". Remove electronic throttle control actuator as follows: Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Refer to CO-11, "Changing Engine Coolant". WARNING: To avoid the danger of being scalded, never drain engine coolant when engine is hot. CAUTION: â&#x20AC;˘ Perform when engine is cold. â&#x20AC;˘ Do not spill engine coolant on drive belt. Disconnect water hoses from electronic throttle control actuator.

Revision: October 2008

EM-25

2009 Xterra

INTAKE MANIFOLD COLLECTOR [VQ40DE] < ON-VEHICLE REPAIR > • When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant leakage. c. Disconnect harness connector. d. Loosen bolts in reverse order as shown. CAUTION: • Handle carefully to avoid any shock to electronic throttle control actuator. • Do not disassemble.

OAHB1764D

5. 6.

Remove the following parts: • Vacuum hose (to brake booster) • PCV hose Loosen bolts in reverse order as shown to remove intake manifold collector support.

OAHB1765D

7. 8. 9.

Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve. Remove EVAP canister purge volume control solenoid valve. Remove VIAS control solenoid valve and vacuum tank. • Add mating marks as necessary for easier installation. 10. Loosen nuts and bolts in reverse order as shown with power tool, and remove intake manifold collector. CAUTION: Cover engine openings to avoid entry of foreign materials.

OAHB1766D

INSTALLATION Installation is in the reverse order of removal. Note the following: Intake Manifold Collector • If stud bolts were removed from intake manifold, install them and tighten to the specified torque.

Revision: October 2008

EM-26

2009 Xterra

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR > • Tighten nuts and bolts in numerical order as shown.

[VQ40DE] A

Intake manifold collector bolts and nuts

: 11.0 N·m (1.1 kg-m, 8 ft-lb) EM

Stud bolts

: 6.9 N·m (7.0kg-m, 61 in-lb) C OAHB1766D

Electronic Throttle Control Actuator • Tighten bolts in numerical order as shown. • Perform the “Throttle Valve Closed Position Learning” when harness connector of electronic throttle control actuator is disconnected. Refer to EC-19, "Throttle Valve Closed Position Learning". • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electronic throttle control actuator is replaced. Refer to EC-19, "Idle Air Volume Learning".

G OAHB1764D

Revision: October 2008

EM-27

2009 Xterra

INTAKE MANIFOLD [VQ40DE]

< ON-VEHICLE REPAIR >

INTAKE MANIFOLD Exploded View

INFOID:0000000004063585

OAHB1767D

Intake manifold

Gasket

Removal and Installation

INFOID:0000000004063586

REMOVAL 1. 2. 3. 4.

Release fuel pressure. Refer to EC-487, "Fuel Pressure Check". Remove intake manifold collector. Refer to EM-25, "Removal and Installation". Remove fuel tube and fuel injector assembly. Refer to EM-44, "Removal and Installation". Loosen nuts and bolts with power tool in reverse order as shown to remove intake manifold.

OAHB1768D

Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion

Revision: October 2008

EM-28

2009 Xterra

INTAKE MANIFOLD < ON-VEHICLE REPAIR > • Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge. Limit

[VQ40DE] A

: 0.1 mm (0.004 in) EM

• If it exceeds the limit, replace intake manifold.

C OAHB/ 76/ D

INSTALLATION Installation is in the reverse order of removal. Note the following: Intake Manifold • If stud bolts were removed from cylinder head, install them and tighten to the specified torque.

Intake manifold studs

: 11.0 N·m (1.1kg-m, 8 ft-lb)

• Tighten all nuts and bolts to the specified torque in two or more steps in numerical order as shown.

Intake manifold bolt and nuts 1st step : 7.4 N·m (0.75 kg-m, 65 in-lb) 2nd step and after : 29.0 N·m (3.0 kg-m, 21 ft-lb)

I OAHB1768D

Revision: October 2008

EM-29

2009 Xterra

EXHAUST MANIFOLD AND THREE WAY CATALYST [VQ40DE]

< ON-VEHICLE REPAIR >

EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View

INFOID:0000000004063587

OAHB177/ D

Exhaust manifold cover (RH)

Exhaust manifold (RH)

Exhaust manifold (LH)

Exhaust manifold cover (LH)

Removal and Installation

Gasket

INFOID:0000000004063588

REMOVAL (LH) WARNING: Perform the work when the exhaust and cooling system have cooled sufficiently. 1. Remove air cleaner case and air duct and resonator assembly. Refer to EM-24, "Removal and Installation". 2. Remove the air dam using power tool. 3. Remove engine undercover using power tool. 4. Disconnect harness connector and remove LH and RH heated oxygen sensor 2 using Tool. Tool number

: KV10114400 (J-38365)

CAUTION: • Be careful not to damage heated oxygen sensor 2. • Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m (19.70 in) onto a hard surface such as a concrete floor; replace with a new sensor. KAH@/ 335D

5. 6.

Remove center exhaust tube, main muffler and left front exhaust tube. Refer to EX-5, "Removal and Installation". Remove exhaust manifold cover (LH).

Revision: October 2008

EM-30

2009 Xterra

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > 7. Disconnect harness connector and remove air fuel ratio sensor 1 (LH) using Tool (A). • : Front Tool number

: KV991J0050 (J-44626)

CAUTION: • Be careful not to damage air fuel ratio sensor 1. • Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. 8. 9.

[VQ40DE]

C @V AH@/ 613YY

Remove three way catalyst LH). Loosen nuts with power tool in reverse order as shown. • : Front NOTE: Disregard the numerical order No. 7 and 8 in removal.

G @V AH@/ 614YY

10. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.

Limit

: 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold. L

M OAHB0/ 85D

INSTALLATION (LH) Installation is in the reverse order of removal.

Exhaust Manifold Gasket Install the exhaust manifold gasket in direction as shown. • : Front • A: Identification hole

@V AH@/ 615YY

Exhaust Manifold Revision: October 2008

EM-31

2009 Xterra

EXHAUST MANIFOLD AND THREE WAY CATALYST < ON-VEHICLE REPAIR > • If stud bolts were removed, install them and tighten to the specified torque. Exhaust manifold stud torque

[VQ40DE]

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

• Install exhaust manifold and tighten nuts in numerical order as shown. CAUTION: Use new exhaust manifold nuts for installation. NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 show second step. : Front

@V AH@/ 614YY

Heated Oxygen Sensor CAUTION: • Do not over tighten air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the “MIL” coming on. • Before installing a new air fuel ratio sensor 1 and heated oxygen sensor 2, clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.

Tool number

: — (J-43897-12) : — (J-43897 18)

REMOVAL (RH) 1. 2.

Remove engine assembly. Refer to EM-102, "Removal and Installation". Loosen nuts with power tool in reverse order as shown. • : Front NOTE: Disregard the numerical order No. 7 and 8 in removal.

@V AH@/ 616YY

Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge.

Limit

: 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.

OAHB0/ 85D

INSTALLATION (RH) Installation is in the reverse order of removal. Revision: October 2008

EM-32

2009 Xterra

EXHAUST MANIFOLD AND THREE WAY CATALYST [VQ40DE]

< ON-VEHICLE REPAIR > Exhaust Manifold Gasket Install the exhaust manifold gaskets in direction as shown. • : Front • A: Identification hole

@V AH@/ 617YY

Exhaust Manifold • If stud bolts were removed, install them and tighten to the specified torque.

Exhaust manifold stud torque

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

@V AH@/ 616YY

Tool number

: :

— —

(J-43897-12) (J-43897-18)

Revision: October 2008

EM-33

2009 Xterra

OIL PAN AND OIL STRAINER [VQ40DE]

< ON-VEHICLE REPAIR >

OIL PAN AND OIL STRAINER Exploded View

INFOID:0000000004063589

OAHB1772D

Oil pan (upper)

Oil pressure switch

O-ring

Relief valve

O-ring

Oil cooler

Connector bolt

Oil filter

Drain plug

10. Drain plug washer

11. Oil pan (lower)

12. Rear cover plate

13. Oil strainer

15. Oil level gauge guide

O-ring

16. Oil level gauge

Removal and Installation

INFOID:0000000004063590

REMOVAL (Lower) WARNING: To avoid the danger of being scalded, do not drain engine oil when engine is hot. 1. Drain engine oil. Refer to LU-8, "Changing Engine Oil". 2. Remove oil pan (lower) as follows:

Revision: October 2008

EM-34

2009 Xterra

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > a. Remove the oil pan (lower) bolts using power tool in reverse order as shown.

[VQ40DE] A

C OAHB178/ D

Insert Tool between the oil pan (lower) and the oil pan (upper). Tool number

: KV10111100 (J-37228)

CAUTION: • Be careful not to damage the mating surfaces. • Do not insert screwdriver, this will damage the mating surfaces. NOTE: Tap (1) Tool to insert it and then slide (2) it by tapping on the side of the Tool as shown.

G V AH@/ 455D

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.

INSTALLATION (Lower) 1. a.

Install oil pan (lower) as follows: Use scraper to remove old liquid gasket from mating surfaces. • Also remove old liquid gasket from mating surface of oil pan (upper). • Remove old liquid gasket from the bolt holes and thread. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

L OAHB1777D

Apply a continuous bead of liquid gasket using Tool to the oil pan (lower) as shown. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". CAUTION: Attaching should be done within 5 minutes after coating.

OAHB1778D

Install oil pan (lower).

Revision: October 2008

EM-35

2009 Xterra

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > • Tighten oil pan (lower) bolts in numerical order as shown.

[VQ40DE]

OAHB178/ D

2. 3.

Install oil pan drain plug. Refer to EM-34, "Removal and Installation". After 30 minutes fill with engine oil and inspect for leaks. Refer to LU-8, "Changing Engine Oil". CAUTION: Do not fill the engine with oil for at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check engine oil level and adjust as needed. Refer to LU-7, "Inspection". Start engine, and check for leaks of engine oil. Stop engine and wait for 10 minutes. Check engine oil level again. Refer to LU-7, "Inspection".

REMOVAL (Upper) WARNING: To avoid the danger of being scalded, do not drain engine oil when engine is hot. CAUTION: • Perform this procedure when engine is cold. • Do not spill engine oil on drive belts. • Do not spill engine coolant on drive belts. 1. Remove engine room cover with power tool. Refer to EM-23, "Removal and Installation". 2. Remove air duct and resonator assembly. Refer to EM-24, "Removal and Installation". 3. Drain engine oil. Refer to LU-8, "Changing Engine Oil". 4. Drain engine coolant. Refer to CO-11, "Changing Engine Coolant". 5. Remove front final drive (4WD models). Refer to DLN-156, "Removal and Installation". 6. Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts, position out of the way. Refer to ST-16, "Removal and Installation". 7. Remove starter motor. Refer to STR-27, "Removal and Installation". 8. Disconnect A/T fluid cooler tube brackets and position out of the way. Refer to TM-268, "Removal and Installation (2WD)" (2WD models), TM-270, "Removal and Installation (4WD)" (4WD models). 9. Remove oil filter, as necessary. Refer to LU-10, "Removal and Installation". 10. Remove oil cooler. Refer to LU-11, "Removal and Installation". 11. Remove oil pan (lower). Refer to EM-34, "Removal and Installation". 12. Remove oil strainer. 13. Remove transmission joint bolts which pierce oil pan (upper). Refer to TM-21, "Removal and Installation from Vehicle (For 2WD Models)" (2WD M/T models), TM-23, "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T models), TM-268, "Removal and Installation (2WD)" (2WD A/T models), TM270, "Removal and Installation (4WD)" (4WD A/T models). 14. Remove rear cover plate.

Revision: October 2008

EM-36

2009 Xterra

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > 15. Remove oil pan (upper) bolts with power tool in reverse order as shown.

[VQ40DE] A

C OAHB1776D

• Insert Tool between oil pan (upper) and lower cylinder block. Tap (1) Tool to insert it and then slide (2) it by tapping on the side as shown. Tool number

: KV10111100 (J-37228) F

CAUTION: Be careful not to damage mating surfaces.

G V AH@/ 455D

16. Remove O-rings from bottom of lower cylinder block and oil pump.

OAHB1774D

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.

INSTALLATION (Upper) 1. a.

Install oil pan (upper) as follows: Use scraper to remove old liquid gasket from mating surfaces. • Also remove the old liquid gasket from mating surface of lower cylinder block. • Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

OAHB1773D

Revision: October 2008

EM-37

2009 Xterra

OIL PAN AND OIL STRAINER < ON-VEHICLE REPAIR > b. Install new O-rings on the bottom of lower cylinder block and oil pump.

[VQ40DE]

OAHB1774D

Apply a continuous bead of liquid gasket using Tool to the lower cylinder block mating surfaces of oil pan (upper) as shown. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". CAUTION: • For bolt holes with mark, apply liquid gasket outside the hole. • Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diameter to area (A). • Attaching should be done within 5 minutes after coating. d.

OAHB1775D

Install oil pan (upper). CAUTION: Install avoiding misalignment of both oil pan gaskets and O-rings. • Tighten oil pan (upper) bolts in numerical order as shown. • There are two types of bolts. M8 × 100 mm (3.97 in) M8 × 25 mm (0.98 in)

: 7, 11, 12, 13 : Except the above

OAHB1776D

2. 3.

Tighten transmission joint bolts. Refer to TM-21, "Removal and Installation from Vehicle (For 2WD Models)" (2WD M/T models), TM-23, "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T models), TM-268, "Removal and Installation (2WD)" (2WD A/T models), TM-270, "Removal and Installation (4WD)" (4WD A/T models). Install oil strainer to oil pan (upper). Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Revision: October 2008

EM-38

2009 Xterra

IGNITION COIL [VQ40DE]

< ON-VEHICLE REPAIR >

IGNITION COIL

Exploded View

INFOID:0000000004063591

G OAHB18/ 0D

Ignition coil

Spark plug

Removal and Installation

INFOID:0000000004063592

REMOVAL (LH) 1. 2. 3. 4. 5.

Remove engine room cover using power tool. Refer to EM-23, "Removal and Installation". Remove air cleaner case and air duct and resonator assembly. Refer to EM-24, "Removal and Installation". Move aside harness, harness bracket, and hoses located above ignition coil. Disconnect harness connector from ignition coil. Remove ignition coil. CAUTION: Do not shock ignition coil.

INSTALLATION (LH)

Installation is in the reverse order of removal.

REMOVAL (RH)

1. 2. 3. 4.

Remove intake manifold collector. Refer to EM-25, "Removal and Installation". Move aside harness, harness bracket, and hoses located above ignition coil. Disconnect harness connector from ignition coil. Remove ignition coil. CAUTION: Do not shock ignition coil.

INSTALLATION (RH) Installation is in the reverse order of removal.

Revision: October 2008

EM-39

2009 Xterra

ROCKER COVER [VQ40DE]

< ON-VEHICLE REPAIR >

ROCKER COVER Exploded View

INFOID:0000000004063593

OAHB18/ 4D

Oil filler cap

O-ring

Rocker cover gasket (RH)

PCV hose

PCV valve

Rocker cover (RH)

PCV hose

Rocker cover gasket (LH)

Rocker cover (LH)

10. PCV hose

Removal and Installation

INFOID:0000000004063594

REMOVAL (LH) 1. 2. 3. 4. 5. 6. 7.

Remove the engine room cover using power tool. Refer to EM-23, "Removal and Installation". Separate engine harness removing their brackets from rocker covers. Remove harness bracket from cylinder head, if necessary. Remove ignition coils. Refer to EM-39, "Removal and Installation". Remove PCV hoses from rocker covers. Remove oil filler cap from rocker cover (LH), if necessary. Remove the rocker cover bolts using power tool in reverse order as shown. â&#x20AC;˘ : Front

Revision: October 2008

EM-40

2009 Xterra

ROCKER COVER [VQ40DE]

< ON-VEHICLE REPAIR >

C @V AH@/ 618YY

8. 9.

Remove rocker cover gaskets from rocker covers. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1). CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

INSTALLATION (LH) 1.

Apply liquid gasket using Tool to joint of rocker cover, cylinder head and camshaft bracket (No. 1) as follows: Tool number

a. b.

: WS39930000 (

—

) G

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-14, "Recommended Chemical Products and Sealants". NOTE: The figure shows an example of LH side [zoomed in shows camshaft bracket (No. 1)]. Apply liquid gasket to joint part of camshaft bracket (a) (No. 1) and cylinder head. Apply liquid gasket (b) 90° to figure (a).

L OAHB1363D

2. 3. 4.

Install new rocker cover gasket to rocker cover. Install rocker cover. • Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover. Tighten the rocker cover bolts in two steps in numerical order as shown. • : Front 1st step 2nd step

: 1.96 N·m (0.20 kg-m, 17 in-lb) : 8.33 N·m (0.85 kg-m, 74 in-lb)

@V AH@/ 618YY

5. 6.

Install oil filer cap to rocker cover (LH), if removed. Install PCV hose. • Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end.

Revision: October 2008

EM-41

2009 Xterra

ROCKER COVER < ON-VEHICLE REPAIR > • When installing, be careful not to twist or come in contact with other parts. 7. Installation of the remaining components is in the reverse order of removal.

[VQ40DE]

REMOVAL (RH) 1. 2. 3. 4. 5. 6. 7. 8.

Remove engine room cover using power tool. Refer to EM-23, "Removal and Installation". Remove intake manifold collector. Refer to EM-25, "Removal and Installation". CAUTION: Perform this step when engine is cold. Separate engine harness removing their brackets from rocker covers. Remove harness bracket from cylinder head (RH). Refer to EM-91, "Removal and Installation". Remove ignition coils. Refer to EM-39, "Removal and Installation". Remove PCV hoses from rocker cover. Remove PCV valve and O-ring from rocker cover (RH), if necessary. Remove the rocker cover bolts using power tool in reverse order as shown. • : Front

@V AH@/ 62/ YY

9. Remove rocker cover gaskets from rocker covers. 10. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1). CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

INSTALLATION (RH) 1.

Apply liquid gasket using Tool to joint part among rocker cover, cylinder head and camshaft bracket (No. 1) as follows: Tool number

a. b.

: WS39930000 (

—

)

OAHB1363D

2. 3.

Install new rocker cover gasket to rocker cover. Install rocker cover.

Revision: October 2008

EM-42

2009 Xterra

ROCKER COVER [VQ40DE] < ON-VEHICLE REPAIR > • Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover. 4. Tighten the rocker cover bolts in two steps in numerical order as shown. • : Front 1st step 2nd step

: 1.96 N·m (0.20 kg-m, 17 in-lb) : 8.33 N·m (0.85 kg-m, 74 in-lb)

@V AH@/ 62/ YY

5. 6. 7.

Install new O-ring and PCV valve to rocker cover (RH), if removed. Install PCV hose. • Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end. • When installing, be careful not to twist or come in contact with other parts. Installation of the remaining components is in the reverse order of removal.

Revision: October 2008

EM-43

2009 Xterra

FUEL INJECTOR AND FUEL TUBE [VQ40DE]

< ON-VEHICLE REPAIR >

FUEL INJECTOR AND FUEL TUBE Exploded View

INFOID:0000000004063595

OAHB1846D

Fuel tube (RH)

O-ring

Fuel tube (LH)

Clip

O-ring (blue)

Fuel injector

O-ring (brown)

O-ring

Spacer

10. Fuel damper

11. Fuel damper cap

12. Quick connector cap

13. Fuel feed hose

Removal and Installation

INFOID:0000000004063596

CAUTION: Do not remove or disassemble parts unless instructed as shown.

REMOVAL WARNING: • Put a “CAUTION FLAMMABLE” sign in the workshop. • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. • Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. • To avoid the danger of being scalded, do not drain engine coolant when engine is hot. 1. Remove intake manifold collector. Refer to EM-25, "Removal and Installation". CAUTION: Perform this step when engine is cold.

Revision: October 2008

EM-44

2009 Xterra

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