NISSAN X-TRAIL 2003 Electronic Repair Manual

SHIFT CONTROL
MT-95
D
E
F
G
H
I
J
K
L
MA
B
MT
Inspection (RS6F51A)ECS004UX
lCheck contact surfaces and sliding area for wear, damage,
bending, etc. If necessary, replace parts.
SHIFT FORK
lCheck if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
SCIA0913E
Item One-side wear specification Sliding width of new part
1st & 2nd 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & 6th 0.2 mm (0.008 in)6.10 - 6.23 mm
(0.2402 - 0.2453 in)
Reverse 0.2 mm (0.008 in)12.80 - 12.93 mm
(0.5039 - 0.5091 in)
SMT801D

MT-96
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
General SpecificationsECS004PE
TRANSAXLE
Engine QR20DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Model code number 8H500 8H868
Number of speed 5 6
Synchromesh typeWarner
Shift pattern
Gear ratio 1st 3.500
2nd 1.9440
3rd 1.258
4th 0.947
5th 0.772
6th — 0.630
Reverse 3.374
Number of teeth Input gear 1st 14
2nd 18
3rd 31
4th 38
5th 44
6th — 46
Reverse 14
Main gear 1st 49
2nd 35
3rd 39
4th 36
5th 34
6th — 29
Reverse 38
Reverse idler gearFront 37
Rear 46
Oil capacity
(Imp pt)2.3 (4)
RemarksReverse synchronizer Installed
Double baulk ring type synchronizer 1st & 2rd synchronizer
SCIA0821ESCIA0955E

SERVICE DATA AND SPECIFICATIONS (SDS)
MT-97
D
E
F
G
H
I
J
K
L
MA
B
MT
FINAL GEAR
Gear End PlayECS004PG
Unit: mm (in)
Clearance Between Baulk Ring and GearECS004PJ
3RD,4TH,5TH,6TH & REVERSE BAULK RING
— 6th for RS6F51A Model—
Unit: mm (in)
1ST AND 2ND DOUBLE BAULK RING
Unit: mm (in) Engine QR20DE YD22DDTi
Transaxle model RS5F51A RS6F51A
Model code number 8H500 8H868
Final gear ratio 4.750 4.428
Number of teeth Final gear/Pinion 76/16 62/14
Side gear/Pinion mate gear 14/10 14/10
Gear End play
1st main gear0.20 - 0.30 (0.0079 - 0.0118)
2nd main gear 0.06 - 0.16 (0.0024 - 0.0063)
3rd input gear0.18 - 0.31 (0.0071 - 0.0122)
4th input gear0.20 - 0.30 (0.0079 - 0.0118)
5th input gear0.06 - 0.16 (0.0024 - 0.0063)
6th input gear (For RS6F51A model) 0.06 - 0.16 (0.0024 - 0.0063)
Standard Wear limit
3rd 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
4th 0.9 - 1.45 (0.035 - 0.0571) 0.7 (0.028)
5th 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
6th (For RS6F51A model) 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
Reverse 0.95 - 1.4 (0.0374 - 0.055) 0.7 (0.028)
Dimension Standard Wear limit
A 0.6 - 0.8 (0.024 - 0.031) 0.2 (0.008)
B 1.3 - 1.5 (0.051 - 0.059) 0.2 (0.008)
SCIA0950E

MT-98
SERVICE DATA AND SPECIFICATIONS (SDS)
Available Snap Rings
ECS004PL
INPUT SHAFT SPACER
*: Always check with the Parts Department for the latest parts information.
**: RS5F51A model only.
5THMAINGEAR
—For RS5F51A Model—
*: Always check with the Parts Department for the latest parts information.
Available C-ringsECS004PM
MAINSHAFT C-RING
*: Always check with the Parts Department for the latest parts information.
Available Thrust WasherECS004PN
INPUT SHAFT THRUST WASHER
End play0-0.1mm(0-0.004in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.71 (0.0673)
1.76 (0.0693)
1.81 (0.0713)
1.86 (0.0732)
1.91 (0.0752)
1.96 (0.0772)32204 8H510**
32204 8H511
32204 8H512
32204 8H513
32204 8H514
32204 8H5152.01 (0.0791)
2.06 (0.0811)
2.11 (0.0831)
2.16 (0.0850)
2.21 (0.0871)
2.26 (0.0890)32204 8H516
32204 8H517
32204 8H518
32204 8H519
32204 8H520
32204 8H521**
End play0-0.1mm(0-0.004in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.85 (0.0728)
1.90 (0.0748)
1.95 (0.0768)
2.00 (0.0787)32204 8H500
32204 8H501
32204 8H502
32204 8H5032.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)32204 8H504
32204 8H505
32204 8H506
32204 8H507
End play0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
2.535 (0.0866)
2.565 (0.1010)
2.595 (0.1022)
2.625 (0.1033)
2.655 (0.1045)
2.685 (0.1057)
2.715 (0.1069)
2.745 (0.1081)
2.775 (0.1093)
2.805 (0.1104)32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H8092.835 (0.1116)
2.865 (0.1128)
2.895 (0.1140)
2.925 (0.1152)
2.955 (0.1163)
2.985 (0.1175)
3.015 (0.1187)
3.045 (0.1199)
3.075 (0.1211)32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
Standard length “C2” 154.7 - 154.8 mm (6.091 - 6.094in)
SCIA1008E

SERVICE DATA AND SPECIFICATIONS (SDS)
MT-99
D
E
F
G
H
I
J
K
L
MA
B
MT
*: Always check with the Parts Department for the latest parts information.
DIFFERENTIAL SIDE GEAR THRUST WASHER
*: Always check with the Parts Department for the latest parts information.
Available Adjusting ShimsECS004PO
MAINSHAFT ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
INPUT SAFT REAR BEARING ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
**: RS5F51A model only.Thickness mm (in) Part number* Thickness mm (in) Part number*
3.84 (0.1512)
3.90 (0.1535)
3.96 (0.1559)32347 8H500
32347 8H501
32347 8H5024.02 (0.1583)
4.08 (0.1606)
4.14 (0.1630)32347 8H503
32347 8H504
32347 8H505
Allowable clearance between side gear and differential case with
washer0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in) Part number*
0.75 (0.0295)
0.80 (0.0315)
0.85 (0.0335)
0.90 (0.0354)
0.95 (0.0374)38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
Standard length “C1” 173.85 - 173.95 mm (6.844 - 6.848in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
0.52 (0.0205)
0.60 (0.0236)
0.68 (0.0268)
0.76 (0.0299)32238 8H500
32238 8H501
32238 8H502
32238 8H5030.84 (0.0331)
0.92 (0.0362)
1.00 (0.0394)
1.08 (0.0425)32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA1009E
End play0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number* Thickness mm (in) Part number*
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
6.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)32225 8H500
32225 8H501
32225 8H502
32225 8H503
32225 8H504
32225 8H505
32225 8H506
32225 8H507
32225 8H508
32225 8H509
32225 8H510
32225 8H5110.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)
1.12 (0.0441)
1.16 (0.0457)
1.20 (0.0472)
1.24 (0.0488)
1.28 (0.0504)
1.32 (0.0520)32225 8H512
32225 8H513
32225 8H514
32225 8H515
32225 8H516
32225 8H517
32225 8H518
32225 8H519
32225 8H520
32225 8H521
32225 8H522
32225 8H5231.36 (0.0520)
1.40 (0.0551)
1.44 (0.0567)
1.48 (0.0583)
1.52 (0.0598)
1.56 (0.0614)
1.60 (0.0630)
1.64 (0.0646)
1.68 (0.0661)
1.72 (0.0677)32225 8H524
32225 8H560
32225 8H561
32225 8H562
32225 8H563
32225 8H564
32225 8H565
32225 8H566
32225 8H567**
32225 8H568**

MT-100
SERVICE DATA AND SPECIFICATIONS (SDS)
MAINSAFT REAR BEARING ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
REVERASE IDLER GEAR ADJUSTING SHIM
*: Always check with the Parts Department for the latest parts information.
6THMAINGEARADJUSTINGSHIM
—For RS6F51A Model—
*: Always check with the Parts Department for the latest parts information.
Av ail abl e Sh imsECS004PP
— Differential Side Bearing Preload and Adjusting Shim
BEARING PRELOAD
*: Install shims which are “deflection of differential case” + “L” in thickness.
DIFFERENTIAL SIDE BEARING ADJUSTING SHIM(S)
*: Always check with the Parts Department for the latest parts information.End play0 - 0.06 mm (0 - 0.0024 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)32238 8H510
32238 8H511
32238 8H512
32238 8H513
32238 8H514
32238 8H515
32238 8H516
32238 8H517
32238 8H5180.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)
0.96 (0.0378)
1.00 (0.0396)
1.04 (0.0409)
1.08 (0.0425)32238 8H519
32238 8H520
32238 8H521
32238 8H522
32238 8H523
32238 8H524
32238 8H560
32238 8H561
End play0.04 - 0.14 mm (0.0016 - 0.0055 in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
1.76 (0.0693)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
2.08 (0.0819)
2.16 (0.0850)32237 8H500
32237 8H501
32237 8H502
32237 8H503
32237 8H504
32237 8H5052.24 (0.0882)
2.32 (0.0913)
2.40 (0.0945)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)32237 8H506
32237 8H507
32237 8H508
32237 8H509
32237 8H510
32237 8H511
End play0-0.1mm(0-0.004in)
Thickness mm (in) Part number* Thickness mm (in) Part number*
0.88 (0.0346)
0.96 (0.0378)
1.04 (0.0409)
1.12 (0.0441)32237 8H560
32237 8H561
32237 8H562
32237 8H5631.20 (0.0472)
1.28 (0.0504)
1.36 (0.0520)32237 8H564
32237 8H565
32237 8H566
Differential side bearing preload: L* 0.15 - 0.21 mm (0.0059 - 0.0083)
Thickness mm (in) Part number* Thickness mm (in) Part number*
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)31438 80X00
31438 80X01
31438 80X02
31438 80X03
31438 80X04
31438 80X050.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.84 (0.0331)
0.88 (0.0346)
0.92 (0.0362)31438 80X06
31438 80X07
31438 80X08
31438 80X09
31438 80X10
31438 80X11

MTC-1
MANUAL AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
C
D
E
F
G
H
I
K
L
M
SECTION
A
B
MTC
MANUAL AIR CONDITIONER
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Wiring Diagrams and Trouble Diagnosis .................. 2
TROUBLE DIAGNOSIS .............................................. 3
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ....................................................... 3
WORK FLOW ........................................................ 3
SYMPTOM TABLE ................................................ 3
Component Parts and Harness Connector Location..... 4
PASSENGER COMPARTMENT ........................... 4
Discharge Air Flow ................................................... 5
Wiring Diagram-HEATER ......................................... 6
Operational Check ................................................... 7
CHECKING BLOWER ........................................... 7
CHECKING DISCHARGE AIR .............................. 7
CHECKING RECIRCULATION ............................. 7
CHECKING TEMPERATURE DECREASE .......... 8
CHECKING TEMPERATURE INCREASE ............ 8
Mode Door ............................................................... 8
Air Mix Door ............................................................. 9
Intake Door Motor Circuit ....................................... 10
INSPECTION FLOW ............................................11
COMPONENT DESCRIPTION ............................11
DIAGNOSTIC PROCEDURE ...............................11
Blower Motor Circuit ............................................... 13
INSPECTION FLOW ........................................... 14
DIAGNOSTIC PROCEDURE .............................. 14
COMPONENT INSPECTION .............................. 17
Insufficient Heating ................................................. 17
INSPECTION FLOW ........................................... 18CONTROLLER .......................................................... 19
Removal and Installation ........................................ 19
Disassembly and Assembly .................................... 19
BLOWER MOTOR .................................................... 20
Removal and Installation ........................................ 20
BLOWER FAN RESISTOR ....................................... 21
Removal and Installation ........................................ 21
INTAKE DOOR MOTOR ........................................... 22
Removal and Installation ........................................ 22
HEATER UNIT ........................................................... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 24
Disassembly and Assembly .................................... 24
HEATER CORE ......................................................... 26
Removal and Installation ........................................ 26
MODE DOOR ............................................................ 27
Control Linkage adjustment .................................... 27
MODE DOOR CONTROL CABLE ....................... 27
AIR MIX DOOR ......................................................... 28
Control Linkage Adjustment ................................... 28
AIR MIX DOOR CONTROL CABLE .................... 28
DUCTS AND GRILLES ............................................. 29
Removal and Installation ........................................ 29
Ventilator Duct, Defroster Nozzle and Defroster
Ducts ...................................................................... 29
Center Ventilator Grille ........................................... 29
Side Ventilator Grille ............................................... 29
Foot Duct ................................................................ 30
Floor duct ................................................................ 30

MTC-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
EJS000W1
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.
WAR NIN G:
lTo 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.
lImproper 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.
lDo 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 harness connectors.
Wiring Diagrams and Trouble DiagnosisEJS000WA
When you read wiring diagrams, refer to the followings:
lGI-14, "How to Read Wiring Diagrams"in GI section.
lPG-3, "Wiring Diagram—POWER—"in EL section.
When you perform trouble diagnosis, refer to the followings:
lGI-10, "How to Follow Trouble Diagnoses"in GI section.
lGI-24, "How to Perform Efficient Diagnosis for an Electrical Incident"in GI section.

TROUBLE DIAGNOSIS
MTC-3
C
D
E
F
G
H
I
K
L
MA
B
MTC
TROUBLE DIAGNOSISPFP:00004
How to Perform Trouble Diagnoses for Quick and Accurate RepairEJS001FB
WORK FLOW
SYMPTOM TABLE
*1 Operational CheckMTC-7
SHA900E
Symptom Reference Page
Air outlet does not change. Go to Trouble Diagnosis Procedure for Mode Door.MTC-27
Discharge air temperature does not change. Go to Trouble Diagnosis Procedure Air Mix Door.MTC-28
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor.MTC-10
Intake door motor does not operate normally.
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor.MTC-13
Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating.MTC-17
Noise. Go to Trouble Diagnosis Procedure for Noise.AT C -9 1

MTC-4
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location
EJS001FC
PASSENGER COMPARTMENT
RJIA0586E