NISSAN X-TRAIL 2003 Service Repair Manual

CLUTCH FLUID
CL-7
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CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS008B9
CAUTION:

Monitor clutch fluid level in reservoir tank to make sure it
does not empty.

Do not spill clutch fluid onto painted surfaces. If it spills,
wipe up immediately and wash the affected area with water.

Bleed the air of operating cylinder.
1. Fill master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in the
clutch fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-10,
"Removal and Installation" .
SCIA1098E
SCL839

CL-8
CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDERPFP:30610
Removal and InstallationECS008BA
—RHD model—
—LHD model—
REMOVAL
1. Using one of the following methods, remove hose from nipple.
PCIB0763E
1. Nipple 2. Clamp 3. Hose
4. Cylinder body 5. Seat 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin
PCIB0764E
1. Nipple 2. Clamp 3. Hose
4. Cylinder body 5. Seat 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin

CLUTCH MASTER CYLINDER
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Drain clutch fluid from reservoir tank and remove hose.

Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
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 torque wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. First remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehi-
cle.
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. Refer to CL-8,
"Removal and Installation" .
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Refer to CL-11,
"Removal and Installation" .
4. Attach clevis of clevis pin to clutch pedal.
5. Attach snap pin to clevis pin.
6. Install hose to nipple.
7. After completing this procedure, inspect and adjust pedal height and then bleed clutch tube. Refer to CL-
5, "On-Vehicle Inspection and Adjustment" , CL-7, "Air Bleeding Procedure"
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin, nipple and seal from cylinder body using a
pin punch.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove seat.
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.

Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole

Damaged or deformed nipple or reservoir tank

Settling of spring

Cracked or deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of cylinder body, sliding surface of piston assembly, and piston
cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install seat.
4. Install clevis to push rod and tighten lock nut to the specified torque. Refer to CL-8, "
Removal and Installa-
tion" .
5. Install seal and nipple to cylinder body. Install spring pin, using a pin punch.
PCIB0274E

CL-10
OPERATING CYLINDER

OPERATING CYLINDERPFP:30620
Removal and InstallationECS008BC
REMOVAL
1. Drain clutch fluid.
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 operating cylinder.
3. Remove operating cylinder mounting bolt and remove operating cylinder from vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.

Install hose with care so that it will not be bent or twisted.

After completing the procedure, bleed clutch tube. Refer to CL-7, "Air Bleeding Procedure" .
Disassembly and AssemblyECS008BD
DISASSEMBLY

Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole

Settling of the spring

Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.
1. Air bleeder valve 2. Copper washer 3. Union bolt
4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring
PCIB0765E

CLUTCH PIPING
CL-11
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CLUTCH PIPINGPFP:30650
Removal and InstallationECS008BE
Carefully observe the following steps during clutch tube removal and installation.

Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.

To fix clutch hose on the bracket, position clutch hose clasp on
the bracket locating emboss and drive lock plate vertically from
above. Be careful not to bend or twist clutch hose. Do not
scratch or damage clutch hose.

Tighten clutch tube flare nut to the specified torque. Refer to CL-
11 , "Removal and Installation" .

Tighten clutch hose union bolt to the specified torque. Refer to
CL-11, "
Removal and Installation" .
CAUTION:
Do not reuse the copper washer.

After installation, bleed clutch tube. Refer to CL-7, "Air Bleeding
Procedure" .
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder 5. Clutch pedal 6. Master cylinder
PCIB0813E
PCIB0812E

CL-12
CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISMPFP:30502
Removal and InstallationECS008BF
REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation" .
2. Remove release bearing, withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove retainer spring from withdrawal lever.
INSPECTION AFTER REMOVAL

If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.

If contact surface of withdrawal lever is excessively worn,
replace it.

If dust cover is cracked, replace it.
INSTALLATION
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 quiver. Wipe off any grease oozing
from the parts.

Be careful not to bring any grease into contact with the clutch disk facing, pressure plate surface,
or flywheel surface.
1. Dust cover 2. Withdrawal lever 3. Retainer spring
4. Release bearing
PCIB0767E
SCL733

CLUTCH RELEASE MECHANISM
CL-13
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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.

Evenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring slid-
ing surface.

Apply 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.

Apply 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

CL-14
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS008BG
—QR engine model—
—YD engine model—
CAUTION:
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-17, "Removal and Installation"
2. Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.
PCIB0768E
1. Flywheel 2. Clutch disc 3. Clutch cover
PCIB0769E
1. Flywheel 2. Clutch disc 3. Clutch cover

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc

Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.

Measure clutch disc spline and input shaft spline backlash at the
circumference of the disc. If outside the specification, replace.

Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc.
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.

Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:

Worn thrust ring will generate a beating noise when tapped at
the rivet with a hammer.

Broken thrust ring will make a clinking sound when cover is shaken up and down.

If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc 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).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
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
Tool number : ST 20050240
PCIB0276E
Allowable flywheel runout:
Vehicles with QR engine models:
Refer to EM-108, "
FLYWHEEL DEFLECTION (M/T
MODELS)" .
Vehicles with YD engine models:
Refer toEM-235, "
FLYWHEEL DEFLECTION" .AEM100

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

INSTALLATION
1. Apply recommended grease to clutch disc 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 quiver. Wipe off any grease oozing
from the parts.
2. Install clutch disc 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. Refer to CL-14, "
Removal and Instal-
lation" .
4. Install manual transaxle. Refer to MT-17, "
Removal and Installa-
tion" .
Engine type Tool number
QR engine KV30101600
YD engine ST20630000
SCIA0909E