NISSAN X-TRAIL 2005 Service Repair Manual

CLUTCH PEDAL
CL-5
D
E
F
G
H
I
J
K
L
MA
B
CL

CLUTCH PEDALPFP:46540
On-Vehicle Inspection and AdjustmentECS001WB
1. Make sure that clevis pin floats freely in bore of clutch pedal. It
should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten lock not.
c. Make sure that clevis pin floats in bore of clutch pedal. It should
not be bound by clutch pedal.
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
clevis pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move clutch pedal up and
down to determine if it moves freely.
b. If any sticking is found, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
and again make sure that clevis pin floats freely in bore of clutch
pedal.
3. Check clutch hydraulic and system components (clutch master
cylinder, clutch operating cylinder, clutch withdrawal lever, clutch
release bearing, etc.) for sticking or binding.
a. If any sticking or binding is found, repair or replace related parts as necessary.
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "
Air Bleeding
Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
PCIB0876E

CL-6
CLUTCH PEDAL

Removal and InstallationECS001WC
COMPONENTS
RHD models
LHD models
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
2. Disconnect ASCD clutch switch harness connector. (With ASCD)
3. Remove snap pin and clevis pin from clevis of clutch master cylinder.
PCIB0877E
1. Clutch pedal assembly 2. Assist spring 3. Bushing
4. Stopper rubber 5. Clevis pin 6. Bushing
7. Stopper rubber 8. Pedal stopper bolt (Without ASCD) 9. ASCD clutch switch (With ASCD)
10. Snap pin
PCIB1452E
1. Clutch pedal assembly 2. Assist spring 3. Bushing
4. Clevis pin 5. Bushing 6. Stopper rubber
7. Pedal stopper bolt (Without ASCD) 8. ASCD clutch switch (With ASCD) 9. Stopper rubber
10. Snap pin 11. Bracket

CLUTCH PEDAL
CL-7
D
E
F
G
H
I
J
K
L
MA
B
CL

4. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
INSPECTION AFTER REMOVAL

Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found,
replace clutch pedal.

Check assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
Installation is the reverse order of removal.
NOTE:
Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing clutch
pedal assembly in vehicle and adjusting the pedal free play.

CL-8
CLUTCH FLUID

CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS008B9
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
CAUTION:

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

Keep painted surface on the body or other parts free of
clutch fluid. 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 to release
air.
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 clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-12,
"Components" .
SCIA1098E
SCL839

CLUTCH MASTER CYLINDER
CL-9
D
E
F
G
H
I
J
K
L
MA
B
CL

CLUTCH MASTER CYLINDERPFP:30610
ComponentsECS00G83
RHD models
LHD models
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

CL-10
CLUTCH MASTER CYLINDER

Removal and InstallationECS008BA
REMOVAL
1. Using one of the following methods, remove hose from nipple.

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:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch tube using a flare nut torque wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. Remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-9, "
Components" .
4. Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-13, "
Removal and Installation" .
5. Set clevis to clutch pedal and insert clevis pin.
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer to CL-5, "
On-Vehicle Inspection and Adjustment" and CL-8, "Air Bleeding Proce-
dure" .
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove seat from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly
popping out.
6. 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 return spring

Cracked or deformed seatLength “L”
RHD models : 125.5 mm (4.80 in)
LHD models : 122.0 mm (4.94 in)
SCIA5158E
PCIB0274E

CLUTCH MASTER CYLINDER
CL-11
D
E
F
G
H
I
J
K
L
MA
B
CL

ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and
piston cup. Insert return spring and piston assembly to cylinder body.
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 to cylinder body.
4. Install seal and nipple to cylinder body. Install spring pin using a pin punch.
5. Install clevis to push rod.
6. Check and adjust the positions of clevis and push rod. After
adjusting “L”, tighten lock nut to the specified torque. Refer to
CL-9, "
Components" .
Length “L”
RHD models : 125.5 mm (4.80 in)
LHD models : 122.0 mm (4.94 in)
SCIA5158E

CL-12
OPERATING CYLINDER

OPERATING CYLINDERPFP:30620
ComponentsECS00G84
Removal and InstallationECS008BC
REMOVAL
1. Drain clutch fluid.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. 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 bolts and remove operating cylinder from the vehicle.
INSTALLATION
Note the following, and 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 the air from the clutch hydraulic system. Refer to CL-8, "Air Bleed-
ing Procedure" .
Disassembly and AssemblyECS008BD
DISASSEMBLY

Remove dust cover and push rod. Then 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 piston 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-13
D
E
F
G
H
I
J
K
L
MA
B
CL

CLUTCH PIPINGPFP:30650
Removal and InstallationECS008BE
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

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

Tighten clutch tube flare nut to the specified torque.

Tighten clutch hose union bolt to the specified torque.
CAUTION:
Do not reuse copper washer.

After installation, bleed the air from the clutch hydraulic system.
Refer to CL-8, "
Air Bleeding Procedure" .
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder 5. Clutch pedal 6. Master cylinder
PCIB0813E
PCIB0681E

CL-14
CLUTCH RELEASE MECHANISM

CLUTCH RELEASE MECHANISMPFP:30502
Removal and InstallationECS008BF
COMPONENTS
QR engine models
YD engine models
REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-19, "Removal and Installation" .
2. Remove release bearing and withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove retainer spring (QR engine models) or snap spring (YD engine models) from withdrawal lever.
PCIB0767E
1. Dust cover 2. Withdrawal lever 3. Retainer spring
4. Release bearing
PCIB1453E
1. Dust cover 2. Withdrawal lever 3. Snap spring
4. Release bearing