NISSAN X-TRAIL 2003 Electronic Repair Manual

CLUTCH MASTER CYLINDER
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CLUTCH MASTER CYLINDERPFP:30610
Removal and InstallationECS00353
REMOVAL
1. Using one of the following methods, remove hose from the nipple.
lDrain clutch fluid from reservoir tank and remove hose.
lRemove hose from the nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from
dripping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Using a flare nut wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. First remove the mounting nuts on the master cylinder assembly, and then the master cylinder assembly
from the vehicle.
INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
2. Install master cylinder assembly and tighten mounting nut to the specified torque.
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque.
4. Attach clevis of the clevis pin to the clutch pedal.
5. Attach snap pin to the clevis pin.
6. Install hose to the nipple.
7. After completing this procedure, inspect and adjust pedal height and then bleed the clutch tube. Refer to
CL-5, "
On-vehicle Inspection and Adjustment",CL-8, "Air Bleeding Procedure"
SCIA0324E
1 Clevis pin 2 Snap pin 3 Clevis
4 Lock nut 5 Dust cover 6 Stopper ring
7 Stopper 8 Push rod 9 Piston assembly
10 Return spring 11 Cylinder body 12 Seal
13 Spring pin 14 Nipple 15 Clamp
16 Hose

CL-10
CLUTCH MASTER CYLINDER
Disassembly and Assembly
ECS00354
DISASSEMBLY
1. Using a pin punch, remove spring pin, nipple and seal from the
cylinder body.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove dust cover.
4. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to reduce possibility of the pis-
ton popping out.
5. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
lDamaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
lDamaged or deformed nipple or reservoir tank
lSettling of the spring
lCracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to internal surface of the cylinder body, sliding surface of piston assembly, and the
piston cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down the push rod
by hand to prevent the piston assembly from popping out.
3. Install dust cover.
4. Install clevis to the push rod and tighten lock nut to the specified torque.
5. Install seal and nipple to the cylinder body. Using a pin punch, install spring pin.
CLB0166D

OPERATING CYLINDER
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OPERATING CYLINDERPFP:30620
Removal and InstallationECS00355
REMOVAL
1. Drainclutchfluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Remove clutch hose from the operating cylinder.
3. Remove operating cylinder mounting bolt and remove operating cylinder.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
lInstall hose with care so that it will not be bent or twisted.
lAfter completing the procedure, bleed the clutch tube. Refer toCL-8, "Air Bleeding Procedure".
Disassembly and AssemblyECS00356
DISASSEMBLY
lRemove dust cover and push rod. Remove piston, piston cup, and piston spring from inside the cylinder
body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
lDamage to cylinder inner surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
lSettling of the spring
lCracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body inner surface and rubber grease to the piston cup and piston.
Insert piston assembly into the cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.
SCIA0325E
1 Cylinder body 2 Piston spring 3 Piston cup
4 Piston 5 Push rod 6 Dust cover
7 Air bleeder 8 Union bolt 9 Copper washer
10 Clutch hose

CL-12
CLUTCH PIPING
CLUTCH PIPING
PFP:30650
Removal and InstallationECS0 01 W I
Carefully observe the following steps during clutch tube removal and installation.
lDo not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
lTo fix clutch hose on the bracket, position hose clasp on the
bracket locating embossment and drive the lock plate vertically
from above. Be careful not to bend or twist the hose. Do not
scratch or damage the clutch hose.
lTighten clutch tube flare nut to the specified torque below:
lTighten clutch hose union bolt to the specified torque:
CAUTION:
Do not reuse the copper washer.
lAfter installation, bleed the clutch tube. Refer toCL-8, "Air Bleeding Procedure"
:15-17N·m(1.5-1.8kg·m,11-13ft·lb)
: 16.7 - 19.6 N·m (1.7 - 2.0 kg·m, 13 - 14 ft·lb)
SCIA0326E

CLUTCH RELEASE MECHANISM
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CLUTCH RELEASE MECHANISMPFP:30502
Removal and InstallationECS001WJ
REMOVAL
1. Remove manual transaxle from the vehicle. Refer toMT-16, "Removal and Installation".
2. Remove release bearing, holder spring, and withdrawal lever from inside the clutch housing.
3. Remove dust cover.
4. Remove retainer spring from the withdrawal lever.
INSPECTION AFTER REMOVEL
lIf release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
lIf contact surface of the withdrawal lever is excessively worn,
replace it.
lIf dust cover is cracked, replace it.
INSTALLATION
CAUTION:
lBe sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
lBe careful not to bring any grease into contact with the clutch disk facing, pressure plate surface,
or flywheel surface.
SCIA0328E
SCL733

CL-14
CLUTCH RELEASE MECHANISM
1. Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
lEvenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring slid-
ing surface.
lApply recommended grease to withdrawal lever ball pin contact surface and inner slots of the release
bearing. The grease surface should be level with the surrounding area.
lApply a thin coat of recommended grease evenly to the release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
2. Install in the reverse order of the removal.
SCL815

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS0 01 W K
CAUTION:
Be careful not to bring any grease into contact with the clutch disk facing, pressure plate surface, or
flywheel surface.
REMOBAL
1. Remove manual transaxle from the vehicle. Refer toMT-16, "Removal and Installation"
2. Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disk.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch disk
lMeasure circumferential runout relative to the clutch disk center
spline. If it is outside the specification, replace the clutch disk.
lMeasure clutch disk spline and input shaft spline backlash at the
circumference of the disk. If outside the specification, replace.
lUsing calipers, measure the depth to the clutch disk facing rivet
heads. If it exceeds the allowable wear limit, replace the facing.
SCIA0329E
Runout limit/diameter of the area to be measured:
1.0 mm (0.039 in) or less/230 mm (9.06 in) dia.
Maximum allowable spline backlash:
1.0 mm (0.039 in)
SCL221
Facing wear limit (depth to the rivet head):
0.3 mm (0.012 in)
SCL229

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Clutch cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (special service tool).
lCheck clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
lWorn thrust ring will generate a beating noise when tapped at
therivetwithahammer.
lBroken thrust ring will make a clinking sound when cover is
shaken up and down.
lIf a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disk contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1. Apply recommended Grease to clutch disk and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
2. Install clutch disk and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
4. Install manual transaxle. Refer toMT-16, "
Removal and Installation"
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
SCL466-C
Allowable flywheel runout:
Vehicles with QR20DE:EM-89, "
Flywheel Deflec-
tion"
Vehicles with
YD22DDTi:EM-208, "Flywheel Deflec-
tion"
AEM100
Engine type Tool number
QR20DE KV30100100
YD22DDTi ST20630000
Tightening torque:
First step : 9.9 - 19 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
Final step : 35 - 44 N·m (3.5 - 4.5 kg·m, 26 - 32 ft·lb)SCIA0909E

SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Clutch Control SystemECS004UY
Clutch Master CylinderECS004UZ
Clutch Operating CylinderECS004V0
Clutch DiskECS001WM
Clutch CoverECS001WN
Clutch PedalECS001WL
Type of clutch control Hydraulic
Inner diameter15.87 mm (5/8 in)
Inner diameter19.05 mm (3/4 in)
Engine type QR20DE YD22DDTi
Model240
Facing size (outer dia. x inner dia.thick-
ness)240 x 160 x 3.5 (9.45 x 6.30 x 0.138)
Thickness of disc assembly with load7.85 - 8.35 mm (0.391 - 0.3287 in) with
4,904 N (500 kg,1,103lb)7.85 - 8.35 mm (0.3.91 - 0.3287 in) with
5,690 N (580.2 kg, 1,279 lb)
Wear limit of facing surface to rivet head 0.3 mm (0.012 in)
Runout limit/diameter of the area to be
measured (mm)1.0 mm (0.04 in) or less/ 230 mm (9.06 in) dai.
Maximum allowable spline backlash 1.0 mm (0.04 in)
Engine type QR20DE YD22DDTi
Model240
Full-load 4904 N (500 kg, 1,103lb) 5,690 N (580.2 kg, 1,279 lb)
Diaphragm spring lever height 37.0 - 39.0 mm (1.46 - 1.54 in)
Uneven limit diaphragm spring toe height 0.7 mm (0.028 in) or less
Engine type QR20DE YD22DDTi
Model240
Pedal height 161 - 171mm (6.34 - 6.73 in)
Pedal height at clutch disengagement 86.1 mm (3.390 in) or more 81.9 mm (3.224 in) or more
Pedal free play 9 - 16 mm (0.35 - 0.63 in)
Clearance between clutch switch
thread end and stopper rubber0.1 - 1.0 mm (0.04 - 0.004 in)

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SERVICE DATA AND SPECIFICATIONS (SDS)