2003 NISSAN X-TRAIL brake pads

REAR DISC BRAKE
BR-37
C
D
E
G
H
I
J
K
L
MA
B
BR

4. Fix piston boot with retaining ring.
CAUTION:

Be sure boot is securely engaged in groove on cylinder
body.

Do not reuse retaining ring.
5. Install sliding pins and sliding pin boots to torque member.
6. Install torque member to axle assembly and tighten mounting
bolts to the specified torque.
CAUTION:
Wipe brake fluid and grease on axle assembly washer seats
and torque member mounting surface. Install torque member to
axle assembly.
7. Install pads, pad retainers, shims, and shim covers to torque member and assemble cylinder body.
8. Tighten sliding pin bolts to the specified torque.
9. Connect brake hose to caliper assembly and tighten union bolts to the specified torque.
CAUTION:
Do not reuse union bolt copper washer.
10. After installing caliper assembly, refill with new brake fluid and bleed air. Refer to BR-9, "
Bleeding Brake
System"
SFIA0158E

BR-38
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEFS000CQ
Unit: mm (in)
Brake PedalEFS000CR
Check ValveEFS000CS
Brake BoosterEFS000CT
Vacuum type
Front Disc BrakeEFS000CU
Front brakeBrake model AD31VD
Cylinder bore diameter 44.4 × 2 (1.748 × 0.08)
Pad
Length x width x thickness132.0 × 52.5 × 11.0
(5.20 × 2.067 × 0.433)
Rotor outer diameter x thickness 280 × 28 (11.02 × 1.10)
Rear brakeBrake model AD9VA
Cylinder bore diameter 34.9 (1.374)
Pad
Length x width x thickness83.0 × 33.0 × 8.5
(3.268 × 1.299 × 0.335)
Rotor outer diameter x thickness 292 × 16 (11.50 × 0.63)
Master cylinder Cylinder bore diameter 25.4 (1)
Control valve Valve model Electronic control type
Brake boosterBooster model C215T
Diaphragm diameterPrimary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid DOT 3 or DOT 4
Pedal play3 - 11 mm (0.12 - 0.43 in)
Looseness at clevis pin 1 - 3 mm (0.04 - 0.12 in)
Brake pedal height (from dash panel top surface)M/T model 156 - 166 mm (6.14 - 6.54 in)
A/T model 164 - 174 mm (6.46 - 6.85 in)
Depressed pedal height under a force of 490 N (50 kg,110.6 lb)
(from dash panel top surface)M/T model 80 mm (3.15 in) or more
A/T model 85 mm (3.35 in) or more
Clearance between threaded end of stop lamp switch and pedal stopper 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Vacuum leakage [at vacuum of 66.7 kPa (-500 mmHg, -19.69
inHg)]Within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds
Vacuum leakage [at vacuum of -66.7 kPa (-500 mmHg, -19.69
inHg)]Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds
Input rod installation standard dimension 125 mm (4.92 in)
Brake typeAD31VD
Brake padStandard thickness (new) 11 mm (0.43 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotorStandard thickness (new) 28.0 mm (1.102 in)
Repair limit thickness 26.0 mm (1.024 in)
Runout limit 0.04 mm (0.0016 in)

SERVICE DATA AND SPECIFICATIONS (SDS)
BR-39
C
D
E
G
H
I
J
K
L
MA
B
BR

Rear Disc BrakeEFS000CV
Brake typeAD9VA
Brake padStandard thickness (new) 8.5 mm (0.335 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotorStandard thickness (new) 16.0 mm (0.63 in)
Repair limit thickness 14.0 mm (0.55 in)
Runout limit 0.07 mm (0.0028 in)

BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION
A
B
BRC

BRAKE CONTROL SYSTEM
ABS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Brake System .................................. 4
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
SYSTEM DESCRIPTION ............................................ 6
System Diagram ....................................................... 6
ABS Function ........................................................... 6
EBD Function ........................................................... 6
Fail-Safe Function .................................................... 6
ABS, EBD SYSTEM .............................................. 6
Hydraulic Circuit Diagram ........................................ 7
CAN COMMUNICATION ............................................ 8
System Description .................................................. 8
CAN Communication Unit ........................................ 8
TYPE 1 .................................................................. 8
TYPE 2 .................................................................. 9
TROUBLE DIAGNOSIS .............................................11
How to Proceed With Diagnosis .............................. 11
BASIC CONCEPT ................................................ 11
DIAGNOSIS FLOWCHART ................................ 12
ASKING COMPLAINTS ...................................... 13
EXAMPLE OF DIAGNOSIS SHEET ................... 13
Component Parts Location ..................................... 14
Schematic .............................................................. 15
Wiring Diagram — ABS — ..................................... 16
Control Unit Input/Output Signal Standard ............. 24
REFERENCE VALUE FROM CONSULT-II ......... 24
CONSULT- II Functions .......................................... 25
CONSULT-II MAIN FUNCTION ........................... 25
CONSULT-II BASIC OPERATION PROCEDURE
... 25
SELF-DIAGNOSIS .............................................. 27
DATA MONITOR ................................................. 29
ACTIVE TEST ..................................................... 31
Correct and Quick Diagnosis ................................. 33DIAGNOSIS PRECAUTIONS ............................. 33
Basic Inspection ..................................................... 34
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 34
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 34
BASIC INSPECTION 3 ABS WARNING LAMP ... 34
Inspection 1: Wheel Sensor System ....................... 35
INSPECTION PROCEDURE .............................. 35
Inspection 2: ABS Actuator and Electric Unit (Con-
trol Unit) 1 ............................................................... 37
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 37
Inspection 4: ABS Actuator Relay or ABS Motor
Relay Power System .............................................. 38
Inspection 5: ABS Actuator and Electric Unit (Con-
trol Unit) 2 ............................................................... 39
Inspection 6: G Sensor System .............................. 40
Inspection 7: CAN Communication System ............ 42
Symptom 1: ABS Works Frequently ....................... 42
Symptom 2: Unexpected Pedal Reaction ............... 43
Symptom 3: Longer Stopping Distance .................. 43
Symptom 4: ABS Does Not Work ........................... 44
Symptom 5: Pedal Vibration and ABS Operation
Noise ...................................................................... 44
WHEEL SENSORS ................................................... 45
Removal and Installation ........................................ 45
REMOVAL ........................................................... 45
INSTALLATION ................................................... 45
G SENSOR ................................................................ 46
Removal and Installation ........................................ 46
SENSOR ROTOR ..................................................... 47
Removal and Installation ........................................ 47
REMOVAL ........................................................... 47
INSTALLATION ................................................... 47
ABS ACTUATOR AND ELECTRIC UNIT (ASSEM-
BLY) ........................................................................... 48
Removal and Installation ........................................ 48

BRC-2
ESP/TCS/ABS
PRECAUTIONS ......................................................... 49
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................. 49
Precautions for Brake System ................................ 49
Precautions for Brake Control ................................ 49
PREPARATION ......................................................... 50
Special Service Tools ............................................. 50
ON-VEHICLE SERVICE ............................................ 51
Adjustment of Steering Angle Sensor Neutral Posi-
tion .......................................................................... 51
SYSTEM DESCRIPTION .......................................... 52
System Diagram ..................................................... 52
ESP Function .......................................................... 52
TCS Function .......................................................... 52
ABS Function .......................................................... 53
EBD Function ......................................................... 53
Fail-Safe Function .................................................. 53
ESP/ TCS SYSTEM ............................................ 53
ABS, EBD SYSTEM ............................................ 53
Hydraulic Circuit Diagram ....................................... 54
CAN COMMUNICATION ........................................... 55
System Description ................................................. 55
CAN Communication Unit ....................................... 55
TYPE 3/TYPE4 .................................................... 55
TYPE 5 ................................................................ 56
TROUBLE DIAGNOSIS ............................................ 58
How to Proceed With Diagnosis ............................. 58
BASIC CONCEPT ............................................... 58
DIAGNOSIS FLOWCHART ................................. 59
ASKING COMPLAINTS ....................................... 60
EXAMPLE OF DIAGNOSIS SHEET .................... 60
Component Parts and Harness Connector Location ... 61
Schematic ............................................................... 62
Wiring Diagram —ESP/TCS/ABS— ..................... 63
LHD MODEL ........................................................ 63
RHD MODEL ....................................................... 69
Control Unit Input/Output Signal Standard .............. 75
REFERENCE VALUE FROM CONSULT-II ......... 75
CONSULT-II Functions ........................................... 77
CONSULT-II MAIN FUNCTION ........................... 77
CONSULT-II BASIC OPERATION PROCEDURE
... 77
SELF-DIAGNOSIS .............................................. 79
DATA MONITOR .................................................. 81
ACTIVE TEST ..................................................... 84
For Fast and Accurate Diagnosis ........................... 86
PRECAUTIONS FOR DIAGNOSIS ..................... 86
Basic Inspection ..................................................... 87
BASIC INSPECTION 1 BRAKE FLUID AMOUNT,
LEAKS, AND BRAKE PADS INSPECTION ......... 87
BASIC INSPECTION 2 POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION .................................................................... 87
BASIC INSPECTION 3 ABS WARNING LAMP,
ESP OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAKE WARNING LAMP INSPEC-TION .................................................................... 88
Inspection 1 Wheel Sensor System ........................ 89
INSPECTION PROCEDURE ............................... 89
Inspection 2 Engine System ................................... 91
Inspection 3 ESP/TCS/ABS Control Unit System ... 91
Inspection 4 Pressure Sensor and the Circuit
between Pressure Sensor and ESP/TCS/ABS Con-
trol Unit. ................................................................... 91
Inspection 5 Steering Angle Sensor and Circuit
between Steering Angle Sensor and ESP/TCS/ABS
Control Unit. ............................................................ 93
Inspection 6 Yaw Rate/Side G sensor and the Circuit
between Yaw Rate/Side G sensor and ESP/TCS/
ABS Control Unit. .................................................... 95
Inspection 7 Solenoid Valve, ESP Switch-over Sole-
noid Valve and Circuit ............................................. 96
Inspection 8 Actuator Motor, Motor Relay and Circuit
... 99
Inspection 9 Actuator Relay and Circuit ................101
Inspection 10 Stop Lamp Switch and Circuit .........103
Inspection 11 ESP/TCS/ABS Control Unit Power
Supply Circuit ........................................................103
Inspection 12 When “EMERGENCY BRAKE” is
indicated in the Self-Diagnosis Results .................105
Inspection 13 When “ST ANG SEN SIGNAL” is Indi-
cated in the Self-Diagnosis Results ......................105
Inspection 14 Brake Fluid Level of Reservoir Tank,
Communication Circuit between ESP/TCS/ABS
Control Unit and Brake Fluid Level Warning Switch .106
Inspection 15 CAN Communication Circuit, ESP/
TCS/ABS Control Unit and Steering Angle Sensor .107
Component Check ................................................107
ESP OFF SWITCH ............................................107
ESP RELAY BOX ...............................................107
ESP ACTUATOR ...............................................108
Symptom 1: ABS Works Frequently. .....................110
Symptom 2: Unexpected Pedal Action .................110
Symptom 3: Longer Stopping Distance ................. 111
Symptom 4: ABS Does Not Work. ........................112
Symptom 5: Pedal Vibration and Noise ................112
Symptom 6: ESP OFF Indicator Lamp Does Not Illu-
minate ...................................................................113
Symptom 7: SLIP Indicator Lamp Does Not Illumi-
nate .......................................................................114
Symptom 8: Vehicle Jerks During ESP/TCS/ABS
Control ..................................................................114
WHEEL SENSORS .................................................116
Removal and Installation .......................................116
SENSOR ROTOR ....................................................117
Removal and Installation .......................................117
REMOVAL ..........................................................117
INSTALLATION ..................................................117
ESP/TCS/ABS CONTROL UNIT .............................118
Removal and Installation .......................................118
REMOVAL ..........................................................118
INSTALLATION ..................................................118
ESP/TCS/ABS ACTUATOR AND RELAY BOX ......119
Removal and Installation .......................................119

BRC-4
[ABS]
PRECAUTIONS

[ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS004GW
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. Information necessary to service the system safely is included in the SRS 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 per-
formed by an authorized NISSAN/INFINITI dealer.

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 Air
Bag Module, see the SRS 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.
Precautions for Brake SystemEFS004GX

Recommended fluid is brake fluid “DOT 3” or “DOT 4”.

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off
and flush area with water immediately.

Never use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause
improper operation.

Using a flare nut torque wrench, securely tighten brake tube
flare nuts.

Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction
is detected, replace part with a new one.

Before working, turn ignition switch OFF and disconnect har-
ness connectors of ABS actuator and electric unit (control unit)
or battery negative terminal.

When installing brake piping, be sure to check torque.
Precautions for Brake ControlEFS004FV

During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal.

Just after starting vehicle after ignition switch ON, brake pedal may vibrate or motor operating noise may
be heard from engine compartment. This is a normal status of operation check.

Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.

When an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnostic servicing. Besides electrical system inspection, check booster operation, brake fluid level, and
oil leaks.

If tyre size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.

If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ABS function
may have a malfunction or error.

If aftermarket parts (car stereo, CD player, etc.) Have been installed, check for incidents such as harness
pinches, open circuits, and improper wiring.
SBR820BA

BRC-34
[ABS]
TROUBLE DIAGNOSIS

Basic InspectionEFS004GD
BASIC INSPECTION 1 BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION
1. Check fluid level in the brake reservoir tank. If fluid level is low, refill the brake fluid.
2. Check the brake piping and around the ABS actuator for leaks. If there is leaking or oozing fluid, check the
following items.

If ABS actuator connection is loose, tighten the piping to the specified torque and re-conduct the leak
inspection to make sure there are no leaks.

If there is damage to the connection flare nut or ABS actuator screw, replace the damaged part and re-
conduct the leak inspection to make sure there are no leaks.

When there is fluid leaking or oozing from a part other than ABS actuator connection, if the fluid is just
oozing out, use a clean cloth to wipe off the oozing fluid and re-check for leaks. If fluid is still oozing out,
replace the damaged part.

When there is fluid leaking or oozing at ABS actuator, if the fluid is just oozing out, use a clean cloth to
wipe off the oozing fluid and re-check for leaks. If fluid is still oozing out, replace ABS actuator body.
CAUTION:
ABS actuator body cannot be disassembled.
3. Check the brake pad degree of wear. Refer to BR-27, "
PAD THICKNESS" in “Front Disc Brake” and BR-
32, "PAD WEAR INSPECTION" in “Rear Disc Brake”.
BASIC INSPECTION 2 POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION
Make sure the battery positive cable, negative cable and ground connection are not loose. In addition, check
the battery voltage to make sure it has not dropped.
BASIC INSPECTION 3 ABS WARNING LAMP
1. Make sure that when the ignition switch is turned ON, the ABS warning lamp turns on for approximately 1
second. If they do not turn on, perform CAN communication system diagnosis. Refer to BRC-42, "
Inspec-
tion 7: CAN Communication System" .
2. Check if the ABS warning lamp turns off approximately 1 second after the ignition switch is turned ON, If it
do not turn off, perform self-diagnosis.
3. if ABS warning lamp has not turned off 10 seconds after the engine has been started, perform self-diagno-
sis of the ABS actuator and electric unit (control unit).
4. Always erase the self-diagnostic results after completing self-diagnosis. Refer to BRC-27, "
Operation Pro-
cedure" .

PRECAUTIONS
BRC-49
[ESP/TCS/ABS]
C
D
E
G
H
I
J
K
L
MA
B
BRC

[ESP/TCS/ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EFS004H7
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. Information necessary to service the system safely is included in the SRS 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 per-
formed by an authorized NISSAN/INFINITI dealer.

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 Air
Bag Module, see the SRS 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.
Precautions for Brake SystemEFS0019O

Recommended fluid is brake fluid “DOT 3” or “DOT 4”.

Never reuse drained brake fluid.

Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed
on painted areas, wash it away with water immediately.

Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system.

Use a flare nut wrench when removing and installing brake
tubes.

When installing brake piping, be sure to check torque.

Before working, turn the ignition switch OFF and disconnect the
connectors for the ESP actuator and control unit or the battery
negative terminal.

Burnish the brake pad contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings, or if a
soft pedal occurs at very low mileage. Refer to BR-31, "
BRAKE
BURNISHING PROCEDURE" .
WARNING:
Clean brakes with a vacuum dust collector to minimize risk of health hazard from powder caused
by friction.
Precautions for Brake ControlEFS0019P

During the ESP/TCS/ABS operation, the brake pedal vibrates lightly and its mechanical noise may be
heard. This is a normal condition.

Just after starting the vehicle after ignition switch ON, the brake pedal may vibrate or the motor operating
noise may be heard from the engine compartment. This is a normal status of the operation check.

The stopping distance may be longer than that of vehicles without ABS when the vehicle drives on rough,
gravel, or snowy (fresh deep snow) road.

If a malfunction is indicated by the ABS warning lamp, or other warning lamps, collect the necessary infor-
mation from the customer (what symptoms are present under what conditions) and find out the possible
causes before starting the service. Besides the electrical system inspection, check the booster operation,
brake fluid level, and oil leaks.

If the tyre size and type are used in a improper combination, or the brake pads are not NISSAN genuine
parts, the stopping distance or steering stability may deteriorate.

If there is a radio, antenna, or antenna lead-in wire (including wiring) near the control unit, the ESP/TCS/
ABS function may have a malfunction or error.

If aftermarket parts (e.g. Car stereo equipment, CD player) have been installed, check harnesses for
pinches, open, and improper wiring.
SBR820BA