This paper addresses the issues of integrated fault parameter estimation, diagnosis and reconfigurable controller design for nonlinear systems without hardware redundancy in the case of actuator failures. A composite Kalman filter for simultaneously state and fault parameter estimation, statistical decisions in fault diagnosis, and activation of controller reconfiguration of impaired system is proposed. Using the information from fault detection and diagnosis scheme, the reconfigurable feedback controller is designed automatically based on nonlinear static state decouple theory.