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Shop manual ô tô NISSAN 2000 Xterra CONTENTS FRONT AXLE 2 Precautions 2 PRECAUTIONS .2 Preparation 2 SPECIAL SERVICE TOOLS 2 COMMERCIAL SERVICE TOOLS 2
BODY & TRIMSECTIONBTCONTENTSPRECAUTIONS .2Service Notice 2Supplemental Restraint System (SRS) ″AIRBAG″ 2PREPARATION .3Special Service Tools 3Commercial Service Tools .3SQUEAK AND RATTLE TROUBLE DIAGNOSES .4Work Flow 4CUSTOMER INTERVIEW .4DUPLICATE THE NOISE AND TEST DRIVE 5CHECK RELATED SERVICE BULLETINS .5LOCATE THE NOISE AND IDENTIFY THE ROOTCAUSE .5REPAIR THE CAUSE .5CONFIRM THE REPAIR .6Generic Squeak and Rattle Troubleshooting 6INSTRUMENT PANEL 6CENTER CONSOLE 6DOORS .6TRUNK .7SUNROOF AND HEADLINER .7SEATS 7UNDERHOOD .7Diagnostic Worksheet 8CLIP AND FASTENER 10Description .10BODY FRONT END .12Removal and Installation .12FRONT BUMPER ASSEMBLY 12BODY REAR END AND OPENER 15Removal and Installation .15REAR BUMPER ASSEMBLY 15FRONT DOOR .18Overhaul 18REAR DOOR .19Overhaul 19INSTRUMENT PANEL ASSEMBLY .20Removal and Installation .20SIDE AND FLOOR TRIM .24Removal and Installation .24DOOR TRIM .27Removal and Installation .27ROOF TRIM .30Removal and Installation .30BACK DOOR TRIM .31Removal and Installation .31EXTERIOR .32Removal and Installation .32FRONT SEAT 37Removal and Installation .37REAR SEAT .38Removal and Installation .38SUNROOF 39Removal and Installation .39WINDSHIELD AND WINDOWS 40Removal and Installation .40REMOVAL .40INSTALLATION 40WINDSHIELD 41REAR SIDE WINDOW 42 REAR VIEW MIRROR .44Removal .44Installation 44DOOR MIRROR .45Removal and Installation .45CAB AND REAR BODY 46Body Mounting .46BODY (ALIGNMENT) 47Alignment .47ENGINE COMPARTMENT 48UNDERBODY 50GIMAEMLCECFECLMTATTFPDAXSUBRSTRSHASCELIDX Service NoticeNGBT0001¼ When removing or installing various parts, place a cloth or padding onto the vehicle body to preventscratches.¼ Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soilor damage them.¼ Apply sealing compound where necessary when installing parts.¼ When applying sealing compound, be careful that the sealing compound does not protrude from parts.¼ When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-vention measures.Supplemental Restraint System (SRS) “AIRBAG”NGBT0002The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along witha seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.The Supplemental Restraint System consists of driver air bag module (located in the center of the steeringwheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring harness andspiral cable. Information necessary to service the system safely is included in the RS section of this ServiceManual.WARNING:¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or deathin the event of a collision which would result in air bag inflation, all maintenance should be per-formed by an authorized NISSAN dealer.¼ Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and AirBag Module, see the RS section.¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. Spiral cable and wiring harness (except “SEAT BELT PRE-TENSIONER”) coverwith yellow insulation either just before the harness connectors or for the complete harness arerelated to the SRS.PRECAUTIONSService NoticeBT-2 Special Service ToolsNGBT0027The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescription(J-39570)Chassis EarABT465Locating the noise(J-43980)Nissan Squeak and RattleKitABT474Locating the noiseCommercial Service ToolsNEBT0028Tool number(Kent-Moore No.)Tool nameDescription(J-39565)Engine EarABT466Locating the noiseGIMAEMLCECFECLMTATTFPDAXSUBRSTRSHASCELIDXPREPARATIONSpecial Service ToolsBT-3 NGBT0026Work FlowNGBT0026S01ABT488CUSTOMER INTERVIEWNGBT0026S0101Interview the costumer, if possible, to determine the conditions that exist when the noise occurs. Use theDiagnostic Worksheet during the interview to document the facts and conditions when the noise occurs andany customers comments; refer to BT-8. This information is necessary to duplicate the conditions that existwhen the noise occurs¼ The customer may not be able to provide a detail description or location of the noise. Attempt to obtain allthe facts and conditions that exist when the noise occurs (or does not occur).¼ If there is more than one noise in the vehicle , be sure to diagnose and repair the noise that the costumeris concerned about. This can be accomplished by test driving the vehicle with the costumer.¼ After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteris-tics are provided so the customer, service adviser and technician are all speaking the same language whendefining the noise.¼ Squeak-(Like tennis shoes on a clean floor)Squeak characteristics include the light contact / fast movement / brought on by road conditions / hard sur-faces = higher pitch noise / softer surfaces = lower pitch noises / edge to surface = chirping.¼ Creak-(Like walking on an old wooden floor)Creak characteristics include firm contact / slow movement / twisting with a rotational movement / pitchdependent on materials / often brought on by activity.¼ Rattle-(Like shaking a baby rattle)Rattle characteristics include the fast repeated contact / vibration or similar movement / loose parts / missingclip or fastener / incorrect clearance.¼ Knock-(Like a knock on a door)Knock characteristics include hollow sound / something repeating / often brought on by driver action.¼ Tick-(Like a clock second hand)Tick characteristics include light contact of light material / loose components / can be caused by driver actionon road conditions .¼ Thump-(Heavy, muffled knock noise)Thump characteristics include softer knock / dead sound often brought on by activity.¼ Buzz-(Like a bumble bee)Buzz characteristics include high frequency rattle / firm contact¼ Often the degree of acceptable noise level will vary depending upon the person.A noise that you may judgeas acceptable may be very irritating to the costumer.¼ Weather conditions, especially humidity and temperature, may have a great effect on noise level.SQUEAK AND RATTLE TROUBLE DIAGNOSESWork FlowBT-4 DUPLICATE THE NOISE AND TEST DRIVENGBT0026S0102If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information onthe Diagnostic Worksheet regarding the conditions or locations of the noise. This information can be used toduplicate the same conditions when you confirm the repair.If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-cate the noise with the vehicle stopped by doing one or all of the following:1) Close a door.2) Tap or push / pull around the area where the noise appears to be coming from.3) Rev the engine.4) Use a floor jack to recreate vehicle “twist”.5) At idle, apply engine load (electric load, half-clutch on M/T model, drive position on A/T model).6) Raise the vehicle on a hoist and hit a tire with rubber hammer.¼ Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.¼ If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress thevehicle body.CHECK RELATED SERVICE BULLETINSNGBT0026S0103After verifying the customer concern or symptom, check ASSIST for Technical Service Bulletins (TSB’s) relatedto that concern or symptom.If a TSB relates to the symptom, follow the procedure to repair the noise.LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSENGBT0026S01041. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool(Chassis Ear : J-39570, Engine Ear : J-39565 and mechanics stethoscope).2. Narrow down the noise to a more specific area and identify the cause of the noise by:¼ Removing the components in the area that you suspect the noise is coming from.Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be brokenor lost during the repair, resulting in the creation of new noise.¼ Tapping or pushing/pulling the component that you suspect is causing the noise.Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only tem-porarily.¼ Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing thenoise.¼ Placing a piece of paper between components that you suspect are causing the noise.¼ Looking for loose components and contact marks.Refer to Generic Squeak and Rattle Troubleshooting,REPAIR THE CAUSENGBT0026S0105¼ If the cause is a loose component, tighten the component securely.¼ If the cause is insufficient clearance between components:− Separate components by repositioning or loosening and retightening the component, if possible.− insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-thane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan PartsDepartment.CAUTION:Do not use excessive force as many components are constructed of plastic and may be damaged.Always check with the Parts Department for the latest parts information.The following material are contained in the Nissan Squeak and Rattle Kit (J-43980) Each item can be orderedseparately as needed.URETHANE PADS (1.5mm thick)insulates connectors, harness, etc.76268–9E005 : 100 x 135mm / 76884–71L01 : 60 x 85mm / 76884–71L02 : 15 x 25mmINSULATOR (foam blocks)Insulates components from contact. Can be used to fill space behind a panel.73982–9E000 : 45mm thick, 50 x 50mm / 73982–50Y00 : 10mm thick, 50 x 50mmGIMAEMLCECFECLMTATTFPDAXSUBRSTRSHASCELIDXSQUEAK AND RATTLE TROUBLE DIAGNOSESWork Flow (Cont’d)BT-5 INSULATOR (Light foam block)80845–71L00 :30mm thick, 30 x 50mmFELT CLOTH TAPEUsed to insulate where movement does not occur. Ideal for instrument panel applications.68370–4B000 : 15 x 25mm pad / 68239–13E00 : 5mm wide tape rollThe following materials, not found in the kit, can also be used to repair squeaks and rattles.UHMW (TEFLON) TAPEInsulates where slight movement is present. Ideal for instrument panel applications.SILICONE GREASEUsed in place of UHMW tape that will be visible or not fit.Note : Will only last a few months.SILICONE SPRAYUse when grease cannot be applied.DUCT TAPEUse to eliminate movement.CONFIRM THE REPAIRNGBT0026S0106Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the sameconditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.Generic Squeak and Rattle TroubleshootingNGBT0026S02INSTRUMENT PANELNGBT0026S0201Most incidents are caused by contact and movement between :1. The lid A and instrument panel2. Acrylic lens and combination meter housing3. Instrument panel to front pillar garnish4. Instrument panel to windshield5. Instrument panel mounting pins6. Wiring harness behind the combination meter7. A/C defroster duct and duct jointThese incidents can usually be located by tapping or moving the components to duplicate the noise or bypressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-ness.CAUTION:Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you willnot be able to recheck the repair.CENTER CONSOLENGBT0026S0202Components to pay attention to include :1. Shifter assembly cover to finisher.2. A/C control unit and cluster lid C3. Wiring harness behind audio and A/C control unitThe instrument panel repair and isolation procedures also apply to center console.DOORSNGBT0026S0203Pay attention to the :1. Finisher an inner panel making a slapping noise2. Inside handle escutcheon to door finisher3. Wiring harnesses tapping4. Door striker out of alignment causing a popping noise on starts and stopsTapping or moving the components or pressing on them while driving to duplicate the conditions can isolatemany of these incidents. You can usually insulate the areas with felt cloth or insulator foam blocks from theNissan Squeak and Rattle Kit (J-43980) to repair the noise.SQUEAK AND RATTLE TROUBLE DIAGNOSESWork Flow (Cont’d)BT-6 TRUNKNGBT0026S0204Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.In addition look for :1. Trunk lid bumpers out of adjustment2. Trunk lid striker out of adjustment3. The trunk lid torsion bars knocking together4. A loose license plate or bracketMost of these incidents can be repaired by adjusting, securing, or insulating the items(s) or components(s)causing the noise.SUNROOF AND HEADLINERNGBT0026S0205Noises in the sunroof and headliner area can often be traced to one of the following:1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise2. Sunvisor shaft shaking in the holder3. Front or rear windshield touching headliner and squeakingAgain, pressing on the components to stop the noise while duplicating the conditions can isolate most of theseincidents. Repairs usually consist of insulating with felt cloth tape.SEATSNGBT0026S0206When isolating seat noises it’s important to note the position the seat in and the load placed on the seat whenthe noise is present.These conditions should be duplicated when verifying and isolating the cause of the noise.Cause of seat noise include :1. Headrest rods and holders2. A squeak between the seat pad cushion and frame3. The rear seat back lock and bracketThese noises can be isolated by moving or pressing on the suspected components while duplicating the con-ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the componentor applying urethane tape to the contact area.UNDERHOODNGBT0026S0207Some interior noises may be caused by components under the hood or on the engine wall. The noise is thentransmitted into the passenger compartment.Causes of transmitted underhood noises include:1. Any components mounted to the engine wall2. Components that pass through the engine wall3. Engine wall mounts and connectors4. Loose radiator mounting pins5. Hood bumpers out of adjustment6. Hood striker out of adjustmentThese noises can be difficult to isolate since they can not be reached from the interior of the vehicle. The bestmethod is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPMor load can be changed to isolate the noise.Repair can usually be made by moving, adjusting, securing, or insulating the component causing the noise.GIMAEMLCECFECLMTATTFPDAXSUBRSTRSHASCELIDXSQUEAK AND RATTLE TROUBLE DIAGNOSESGeneric Squeak and Rattle Troubleshooting (Cont’d)BT-7 Diagnostic WorksheetNGBT0026S03ABT468SQUEAK AND RATTLE TROUBLE DIAGNOSESDiagnostic WorksheetBT-8 ABT469GIMAEMLCECFECLMTATTFPDAXSUBRSTRSHASCELIDXSQUEAK AND RATTLE TROUBLE DIAGNOSESDiagnostic Worksheet (Cont’d)BT-9 DescriptionNGBT0003¼ Clips and fasteners in BT section correspond to the following numbers and symbols.¼ Replace any clips and/or fasteners which are damaged during removal or installation.Symbol No. Shapes Removal & InstallationC101SBF302HSBF367BAC103SBT095SBF423HC203SBF258GSBF708ECE103SBF104BSBF147BCLIP AND FASTENERDescriptionBT-10 [...]... EL BT-15 IDX BODY REAR END AND OPENER Removal and Installation (Cont’d) ABT443 BT-16 BODY REAR END AND OPENER Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT444 EL BT-17 IDX FRONT DOOR Overhaul Overhaul ¼ ¼ NGBT0006 For removal of door trim, refer to “Door Trim” for details, BT-27 After adjusting door or door lock, check door lock operation ABT481 BT-18 REAR... LC EC FE ABT482 *3 CL BT-24 MT AT TF PD AX SU BR ST RS HA SC EL BT-21 IDX INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) ABT445 BT-22 INSTRUMENT PANEL ASSEMBLY Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT404 EL BT-23 IDX SIDE AND FLOOR TRIM Removal and Installation Removal and Installation CAUTION: Wrap the tip of flat-bladed screwdriver with... seats Refer to “FRONT SEAT” and “REAR SEAT” for details,BT-37, 38 front and rear seat belts Refer to “SEAT BELTS” for details, RS-4, RS-5 body side trim Refer to “SIDE AND FLOOR TRIM”for details, BT-24 sun visors assist grips interior lamp assembly and luggage room lamp assembly clips securing headliner coat hooks sunroof welt headliner ABT471 BT-30 BACK DOOR TRIM Removal and Installation Removal and... ABT451 HA SC EL BT-31 IDX EXTERIOR Removal and Installation Removal and Installation NGBT0013 ABT453 BT-32 EXTERIOR Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT454 EL BT-33 IDX EXTERIOR Removal and Installation (Cont’d) ABT455 BT-34 EXTERIOR Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT456 EL BT-35 IDX EXTERIOR... ABT489 BT-19 EL IDX INSTRUMENT PANEL ASSEMBLY Removal and Installation Removal and Installation NGBT0008 CAUTION: ¼ Disconnect both terminals from battery in advance ¼ Disconnect air bag module connectors in advance ¼ Be careful not to scratch finishers and other parts ¼ Never tamper with or force air bag lid open, as this may adversely affect air bag performance ABT446 *1 ST-10 *2 RS-19 BT-20 INSTRUMENT... securing door finisher 11 Lift out door finisher NGBT0010 GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC EL BT-27 IDX DOOR TRIM Removal and Installation (Cont’d) ABT447 BT-28 DOOR TRIM Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT299 EL BT-29 IDX ROOF TRIM Removal and Installation Removal and Installation 1 2 3 4 5 6 7 8 9 10 Remove Remove Remove Remove... bolts securing left and right bumper from bumper brackets Remove bumper assembly Separate bumper assembly BT-12 BODY FRONT END Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT487 EL BT-13 IDX BODY FRONT END Removal and Installation (Cont’d) ABT450 BT-14 BODY REAR END AND OPENER Removal and Installation Removal and Installation ¼ ¼ Remove Remove Remove Remove... SIDE AND FLOOR TRIM Removal and Installation (Cont’d) GI MA EM LC EC FE CL MT AT TF PD AX SU BR ST RS HA SC ABT442 EL BT-25 IDX SIDE AND FLOOR TRIM Removal and Installation (Cont’d) ABT472 BT-26 DOOR TRIM Removal and Installation Removal and Installation Door trim (Formed type) Remove manual window regulator handle, if equipped 1 Remove inside handle escutcheon 2 Remove door armrest 3 Remove screw securing... SEAT” for details,BT-37, 38 2 Remove front and rear kicking plates 3 Remove dash side lower finishes 4 Remove front and rear body side welts 5 Remove front pillar garnishes 6 Remove center pillar lower garnishes 7 Remove center pillar upper garnishes 8 Remove rear gate kicking plate 9 Remove rear wheel well garnish 10 Remove rear side lower garnishes 11 Remove rear side upper garnishes BT-24 NGBT0009 SIDE... Symbol No Shapes Removal & Installation GI MA CG104 EM SBF352C SBF351C LC EC CE114 — FE SBF353C CL MT CG101 AT SBF145B TF SBF085B PD AX CR103 SU SBF768B BR SBF770B ST RS CS101 HA SBF078B SBF992G SC EL BT-11 IDX BODY FRONT END Removal and Installation Removal and Installation ¼ ¼ ¼ ¼ ¼ FRONT BUMPER ASSEMBLY 1 2 3 4 5 6 NGBT0004 When removing or installing hood, place a cloth or other padding on hood This . nameDescription(J-39570)Chassis EarABT465Locating the noise(J-43980 )Nissan Squeak and RattleKitABT474Locating the noiseCommercial Service ToolsNEBT0028Tool number(Kent-Moore. blocks, felt cloth tape or ure-thane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan PartsDepartment.CAUTION:Do