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EI


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I BODY

                                                                                                                                                              A


                                                                                                                                                              B
                                                                                                           SECTION
                                                                                    EXTERIOR & INTERIOR                                                       C


                                                                                                                                                              D


                                                                                                                                                              E
                                                                CONTENTS
PRECAUTIONS ......................................................... 3
                                                                      .         FRONT GRILLE ....................................................... 16
                                                                                                                                                    .         F
 Precautions for Supplemental Restraint System                                   Removal and Installation ....................................... 16.
 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                           REMOVAL .......................................................... 16
                                                                                                                                                    .
 SIONER" ................................................................. 3
                                                                      .            INSTALLATION .................................................. 16
                                                                                                                                                    .         G
 Service Notice ......................................................... 3
                                                                      .         COWL TOP .............................................................. 17
                                                                                                                                                    .
PREPARATION .......................................................... 4
                                                                      .          Removal and Installation ....................................... 17.
 Special Service Tools .............................................. 4
                                                                      .            REMOVAL .......................................................... 17
                                                                                                                                                    .
                                                                                                                                                              H
 Commercial Service Tools ....................................... 4   .            INSTALLATION .................................................. 17
                                                                                                                                                    .
SQUEAK AND RATTLE TROUBLE DIAGNOSES..... 5                                      FRONT FENDER ..................................................... 18
                                                                                                                                                    .
 Work Flow ............................................................... 5
                                                                      .          Removal and Installation ....................................... 18.
   CUSTOMER INTERVIEW .................................... 5          .            REMOVAL .......................................................... 18
                                                                                                                                                    .        EI
   DUPLICATE THE NOISE AND TEST DRIVE ...... 6                        .            INSTALLATION .................................................. 18
                                                                                                                                                    .
   CHECK RELATED SERVICE BULLETINS .......... 6                       .         FENDER PROTECTOR ........................................... 19     .
   LOCATE THE NOISE AND IDENTIFY THE                                             Front Fender Protector .......................................... 19
                                                                                                                                                    .         J
   ROOT CAUSE ..................................................... 6 .            REMOVAL .......................................................... 19
                                                                                                                                                    .
   REPAIR THE CAUSE .......................................... 6      .            INSTALLATION .................................................. 19
                                                                                                                                                    .
   CONFIRM THE REPAIR ...................................... 7        .          Rear Fender Protector ........................................... 20
                                                                                                                                                    .
                                                                                                                                                              K
 Generic Squeak and Rattle Troubleshooting .......... 7               .            REMOVAL .......................................................... 20
                                                                                                                                                    .
   INSTRUMENT PANEL ......................................... 7       .            INSTALLATION .................................................. 20
                                                                                                                                                    .
   CENTER CONSOLE ............................................ 7      .         RUNNING BOARDS ................................................ 21  .
   DOORS ................................................................ 7
                                                                      .          Removal and Installation ....................................... 21.         L
   TRUNK ................................................................. 8
                                                                      .            REMOVAL .......................................................... 21
                                                                                                                                                    .
   SUNROOF/HEADLINING .................................... 8          .            INSTALLATION .................................................. 21
                                                                                                                                                    .
   OVERHEAD CONSOLE (FRONT AND REAR)..... 8                                     ROOF RACK ............................................................ 22
                                                                                                                                                    .         M
   SEATS .................................................................. 8
                                                                      .          Removal and Installation ....................................... 22.
   UNDERHOOD ...................................................... 8 .            REMOVAL .......................................................... 22
                                                                                                                                                    .
 Diagnostic Worksheet ............................................. 9 .            INSTALLATION .................................................. 22
                                                                                                                                                    .
CLIP AND FASTENER .............................................11     .         DOOR OUTSIDE MOLDING .................................... 23        .
 Clip and Fastener ...................................................11
                                                                      .          Removal and Installation ....................................... 23.
FRONT BUMPER .................................................... 14  .            FRONT DOOR OUTSIDE MOLDING ................. 23                  .
 Removal and Installation ....................................... 14  .         DOOR FINISHER ..................................................... 24
                                                                                                                                                    .
   REMOVAL .......................................................... 14
                                                                      .          Removal and Installation ....................................... 24.
   INSTALLATION .................................................. 14 .            FRONT DOOR ................................................... 24.
REAR BUMPER ...................................................... 15 .            REAR DOOR ...................................................... 25
                                                                                                                                                    .
 Removal and Installation ....................................... 15  .         BODY SIDE TRIM .................................................... 27
                                                                                                                                                    .
   REMOVAL .......................................................... 15
                                                                      .
   INSTALLATION .................................................. 15 .




Revision: February 2006                                                    EI-1                                                           2005 Xterra
 Components .......................................................... 27
                                                                   .        HEADLINING ............................................................31
                                                                                                                                                .
 Removal and installation ........................................ 28
                                                                   .         Removal and Installation ........................................31.
   LOWER DASH SIDE FINISHER ........................ 28            .          REMOVAL ...........................................................31
                                                                                                                                                .
   CENTER PILLAR LOWER FINISHER ............... 28                 .          INSTALLATION ...................................................32.
   CENTER PILLAR UPPER FINISHER ................ 28                .        LUGGAGE FLOOR TRIM ........................................33       .
   FRONT PILLAR UPPER FINISHER ................... 28              .         Components ...........................................................33
                                                                                                                                                .
   FRONT PILLAR LOWER FINISHER .................. 28               .         Removal and Installation ........................................35.
   KICK PLATES ..................................................... 28
                                                                   .          REMOVAL ...........................................................35
                                                                                                                                                .
FLOOR TRIM ........................................................... 30
                                                                   .          INSTALLATION ...................................................35.
 Removal and Installation ....................................... 30
                                                                   .        BACK DOOR TRIM ..................................................36 .
   REMOVAL .......................................................... 30
                                                                   .         Removal and Installation ........................................36.
   INSTALLATION ................................................... 30
                                                                   .          REMOVAL ...........................................................36
                                                                                                                                                .
                                                                              INSTALLATION ...................................................36.




Revision: February 2006                                                 EI-2                                                          2005 Xterra
                                              PRECAUTIONS

PRECAUTIONS                                                         PFP:00001
                                                                                                                         A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER"                                                                                           EIS0068Q


The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along                            B
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              C
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 SRS and SB section of this Service Man-
ual.
WARNING:                                                                                                                 D
G    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.                                                                     E
G    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.                                                                                    F
G    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.
                                                                                                                         G
Service Notice                                                                                                EIS0068P


G   When removing or installing various parts, place a cloth or padding on the vehicle body to prevent
    scratches.                                                                                                       H
G   Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not to soil
    or damage them.
G   Apply sealing compound where necessary when installing parts.                                                   EI
G   When applying sealing compound, be careful that the sealing compound does not protrude from parts.
G   When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust pre-
                                                                                                                     J
    vention measures.


                                                                                                                         K


                                                                                                                         L



                                                                                                                         M




Revision: February 2006                                EI-3                                            2005 Xterra
                                            PREPARATION

PREPARATION                                                                                              PFP:00002

Special Service Tools                                                                                        EIS0068R


The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number
  (Kent-Moore No.)                                                      Description
  Tool name
       --                                                               Locating the noise
  (J-39570)
  Chassis ear




                                                               SBT839


       --                                                               Repairing the cause of noise
  (J-43980)
  NISSAN Squeak and Rattle kit




                                                               SBT840



Commercial Service Tools                                                                                     EIS0068S


  (Kent-Moore No.)
                                                                        Description
  Tool name
  (J-39565)                                                             Locating the noise
  Engine ear




                                                            SIIA0995E




Revision: February 2006                              EI-4                                              2005 Xterra
                       SQUEAK AND RATTLE TROUBLE DIAGNOSES

SQUEAK AND RATTLE TROUBLE DIAGNOSES                                                                       PFP:00000
                                                                                                                           A
Work Flow                                                                                                       EIS0068T




                                                                                                                           B



                                                                                                                           C


                                                                                                                           D


                                                                                                                           E



                                                                                                                           F



                                                                                                            SBT842
                                                                                                                           G

CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag- H
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer to EI-9, "Diagnostic Worksheet" . This information is necessary to duplicate the
conditions that exist when the noise occurs.
                                                                                                                       EI
G    The customer may not be able to provide a detailed description or the location of the noise. Attempt to
     obtain all the facts and conditions that exist when the noise occurs (or does not occur).
G    If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
                                                                                                                        J
     is concerned about. This can be accomplished by test driving the vehicle with the customer.
G    After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
     are provided so the customer, service adviser and technician are all speaking the same language when
     defining the noise.                                                                                                K
G    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.                        L
G    Creak--(Like walking on an old wooden floor)
     Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
     dependent on materials/often brought on by activity.                                                               M
G    Rattle--(Like shaking a baby rattle)
     Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
     clip or fastener/incorrect clearance.
G    Knock --(Like a knock on a door)
     Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
G    Tick--(Like a clock second hand)
     Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
     action or road conditions.
G    Thump--(Heavy, muffled knock noise)
     Thump characteristics include softer knock/dead sound often brought on by activity.
G    Buzz--(Like a bumble bee)
     Buzz characteristics include high frequency rattle/firm contact.
G    Often the degree of acceptable noise level will vary depending upon the person. A noise that you may
     judge as acceptable may be very irritating to the customer.
G    Weather conditions, especially humidity and temperature, may have a great effect on noise level.


Revision: February 2006                                EI-5                                            2005 Xterra
                       SQUEAK AND RATTLE TROUBLE DIAGNOSES

DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate 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 (electrical load, A/T in drive position).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.
G    Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
G    If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
     vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to 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 CAUSE
1.   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 mechanic's stethoscope).
2.   Narrow down the noise to a more specific area and identify the cause of the noise by:
G    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 bro-
     ken or lost during the repair, resulting in the creation of new noise.
G    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
     temporarily.
G    feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
     noise.
G    placing a piece of paper between components that you suspect are causing the noise.
G    looking for loose components and contact marks.
     Refer to EI-7, "Generic Squeak and Rattle Troubleshooting" .
REPAIR THE CAUSE
G   If the cause is a loose component, tighten the component securely.
G   If the cause is insufficient clearance between components:



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