NISSAN X-TRAIL 2005 Service Repair Manual

POWER STEERING GEAR AND LINKAGE
PS-19
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DISASSEMBLY
1. Remove cylinder tubes from gear housing assembly.
2. Remove rear cover cap from gear sub assembly.
3. Measure adjusting screw height “H”, and loosen adjusting
screw.
CAUTION:

Do not loosen adjusting screw 2 turns or more.

Replace steering gear assembly if adjusting screw is
loosened 2 turns or more and it is removed.
4. Remove mounting bolts of gear sub assembly, then remove
gear sub assembly from gear housing assembly.
CAUTION:
Do not overhaul gear sub assembly because it is non over-
haul part. If there is something wrong with gear sub-assem-
bly, change it to new one.
5. Remove O-ring C from gear housing assembly.
6. Loosen outer socket lock nut, and remove outer socket.
7. Remove boot clamp on the small and big ends, and remove
boot.
CAUTION:
Do not damage inner socket and gear housing assembly
when removing boot. Inner socket and gear housing
assembly must be replaced if inner socket and gear hous-
ing assembly are damaged because it may cause foreign
material interfusion.
8. Move spacer ring to rack assembly side, raise caulking part (at
two points of part A) of lock plate and loosen inner socket, then
remove inner socket from rack assembly.
CAUTION:
When removing lock plate, be careful not to damage the surface of rack assembly. If damaged rack
assembly surface will cause oil leak. Therefore, if the rack assembly surface is damaged, replace
rack assembly.
1. Outer socket 2. Inner socket 3. Boot clamp
4. Boot 5. Boot clamp 6. Lock plate
7. Spacer 8. Rack assembly 9. Rack Teflon ring
10. O-ring A 11. Rear cover cap 12. Rear housing assembly
13. O-ring B 14. Pinion assembly 15. O-ring C
16. Cylinder tubes 17. Gear housing assembly 18. Rack oil seal
19. End cover assembly
SGIA0624E
SGIA0018E
SGIA0363E

PS-20
POWER STEERING GEAR AND LINKAGE

9. Drill out the punch crimping part of gear housing assembly outer
rim with a 3 mm (0.12 in) drill bit. [Drill for approximately 1.5 mm
(0.059 in) depth.]
10. Remove end cover assembly with a 36 mm (1.42 in) open head
(suitable tool).
CAUTION:
Do not damage rack assembly surface when removing.
Rack assembly must be replaced if damaged because it
may cause oil leakage.
11. Pull rack assembly together with rack oil seal out from gear
housing assembly.
CAUTION:
Do not damage cylinder inner wall when removing rack
assembly. Gear housing assembly must be replaced if dam-
aged because it may cause oil leakage.
12. Heat rack Teflon ring to approximately 40°C (104°F) with a
dryer, and remove rack Teflon ring and O-ring A from rack
assembly.
CAUTION:
Do not damage rack assembly. Rack assembly must be
replaced if damaged because it may cause oil leakage.
13. Push rack oil seal inside with a 29 mm (1.14 in) socket and an
extension bar to push out rack oil seal from gear housing
assembly.
CAUTION:
Do not damage gear housing assembly and cylinder inner
wall. Gear housing assembly must be replaced if damaged
because it may cause oil leakage.
INSPECTION AFTER DISASSEMBLY
Boot
Check boot for cracks. Replace if there are.
Rack Assembly
Check rack assembly for damage or wear. Replace if there are.
Gear Sub Assembly

Check pinion gear for damage or wear. Replace if there are.

Rotate pinion and check for torque variation or rattle. Replace if there are.
STC0013D
SST081B
SGIA0151E
SGIA0179E

POWER STEERING GEAR AND LINKAGE
PS-21
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Gear Housing Assembly
Check gear housing assembly for damage and scratches (inner wall). Replace if there are.
Outer Socket and Inner Socket
1. Swinging torque

Hook a spring balance at the point shown in the figure and
pull the spring balance. Make sure that the spring balance
reads the specified value when ball stud and inner socket
start to move. Replace outer socket and steering gear assem-
bly if they are outside the standard.
2. Rotating Torque

Make sure that the reading is within the following specified
range using the preload gauge [SST]. Replace outer socket if
the reading is outside the specified value.
3. Axial end play

Apply an axial load of 490 N (50 kg, 111 lb) to ball stud using a
dial indicator. Measure amount of stud movement, and then
make sure that the value is within the following specified
range. Replace outer socket and steering gear assembly if
the measured value is outside the standard.
SGIA0896E
Items Outer socket Inner socket
Measuring point of spring
balanceStud cotter pin mounting holeMeasuring point at * mark shown
in the figure
Swinging torque 0.3 - 2.9 N·m
(0.03 - 0.29 kg-m, 3.0 - 25 in-lb)1.0 - 7.8 N·m
(0.10 - 0.80 kg-m, 9.0 - 69 in-lb)
Spring balance measurement 4.84 - 47.4 N
(0.49 - 4.84 kg, 1.08 - 10.7 lb)5.2 - 41 N
(0.53 - 4.1 kg, 1.17 - 9.07 lb)
Outer socket
rotating torque0.3 - 2.9 N·m
(0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
SGIA0083E
Outer socket : 0.5 mm (0.02 in) or less
Inner socket : 0.2 mm (0.008 in) or less
SGIA0057E

PS-22
POWER STEERING GEAR AND LINKAGE

ASSEMBLY
1. Apply Type DEXRONTM III or equivalent to O-ring A. Put an O-ring A into rack Teflon ring.
2. Heat rack Teflon ring to approximately 40°C (104°F) with a
dryer. Assemble it to mounting groove of rack assembly.
3. Install the Teflon ring correcting tool [SST] from tooth side of
rack to fit rack Teflon ring on rack. Compress the ring with tool.
4. Apply multi-purpose grease to rack oil seal and install rack oil
seal, and then assemble rack assembly to gear housing assem-
bly.
CAUTION:

Do not damage retainer sliding surface by rack assembly.
Replace gear housing assembly if damaged.

Do not damage gear housing assembly inner wall by rack
assembly. Gear housing assembly must be replaced if
damaged because it may cause oil leakage.

Install rack oil seal in a direction so that the lip of inner oil
seal and the lip of outer oil seal face each other.
a. Wrap an OHP sheet [approximately 70 mm (2.76 in)×100 mm
(3.94 in).] Around rack assembly teeth to avoid damaging rack
oil seal (inner). Install rack oil seal over sheet. Then, pull oil seal
along with OHP sheet until they pass rack assembly teeth, and
remove OHP sheet.
SGIA0153E
SGIA1207E
SGIA0205E
SGIA0097E

POWER STEERING GEAR AND LINKAGE
PS-23
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b. Insert rack oil seal (inner) into rack assembly piston (rack Teflon
ring). Push retainer to adjusting screw side by hand, and move
the rack assembly inside the gear housing assembly so that the
rack oil seal (inner) can be pressed against the gear housing
assembly.
c. Wrap an OHP sheet [approximately 70 mm (2.76 in)×100 mm
(3.94 in).] Around the edge to avoid damaging rack oil seal
(outer). Install rack oil seal over sheet. Then, pull oil seal along
with OHP sheet until they pass rack edge, and remove OHP
sheet.
d. Install end cover assembly to rack edge, and move rack assem-
bly until it contacts with gear housing assembly.
5. Tighten end cover assembly to specified torque using a 36 mm
(1.42 in) open head (suitable tool).
CAUTION:
Do not damage rack assembly. Replace it if damaged
because it may cause oil leakage.
6. Crimp gear housing assembly at one point using a punch as
shown in the figure so as to prevent end cover assembly from
getting loose after tightening end cover assembly.
7. Apply Type DEXRON
TM III or equivalent to O-ring C, and then
install O-ring C to gear housing assembly.
8. Install gear sub assembly to gear housing assembly.
9. Install inner socket to rack assembly according to the instruc-
tions.
a. Attach spacer ring to rack assembly.
b. Install lock plate to inner socket.
c . A p p l y l o c k i n g s e a l a n t ( T h r e e B o n d T B 1111 o r e q u i v a l e n t ) t o t h e
thread of inner socket. Screw inner socket into rack assembly
and tighten at the specified torque.
d. Clinch lock plate at two points on rack groove.
e. Install spacer ring to lock plate as shown in the figure.
SGIA0935E
SGIA0157E
SST081B
SGIA0871E
SST866C

PS-24
POWER STEERING GEAR AND LINKAGE

CAUTION:
When installing spacer ring, avoid damaging it.
10. Decide on the neutral position for the rack.
11. Install rear cover cap to gear sub assembly.
CAUTION:
Make sure that the projection of rear cover cap is aligned
with the marking position of gear housing assembly.
1 2 . A p p l y a c o a t o f T h r e e B o n d T B 1111 o r e q u i v a l e n t t o t h e t h r e a d
(2 turns thread), and then screw in the adjusting screw until it
reaches height “H” from gear housing assembly measured
before disassembling.
13. Move rack 10 strokes throughout the full stroke so that the parts
can fit with each other.
14. Measure pinion rotating torque within ±180° of neutral position
of the rack using the preload gauge [SST] and preload adapter
[SST]. Stop the gear at the point where highest torque is read.
15. Loosen adjusting screw and retighten to 5.4 N·m (0.55 kg-m, 48
in-lb), and then loosen by 20 to 40°.
16. Measure pinion rotating torque using the steering gear preload
adapter [SST] and preload gauge [SST] to make sure that the
measured value is within the standard. Readjust if the value is
outside the standard. Replace gear assembly if the value is out
side the standard after readjusting or adjusting screw rotating
torque is 5 N·m (0.51 kg-m, 44 in-lb) or less.
1 7 . A p p l y a c o a t o f T h r e e B o n d T B 1111 o r e q u i v a l e n t t o i n n e r s o c k e t a n d t u r n p i n i o n f u l l y t o l e f t w i t h i n n e r
socket installed to gear housing assembly.Rack stroke “L” : 66.5 mm (2.618 in)
SGIA0629J
SGIA0624E
STC0036D
Pinion rotating torque standard
Around neutral position
(Within±100°) Average A1.67–2.25 N·m
(0.17 – 0.22 kg-m, 1.3 – 1.6 ft-lb)
Maximum variation B 0.98 N·m (0.10 kg-m, 1 ft-lb)
SGIA0936E

POWER STEERING GEAR AND LINKAGE
PS-25
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18. Set dial gauge as shown in the figure. Measure vertical move-
ment of rack assembly when pinion is turned clockwise with
torque of 4.9 N·m (0.5 kg-m, 43 in-lb). Readjust adjusting screw
angle if the measured value is outside the standard. Replace
gear assembly if the measured value is still outside the standard
or adjusting screw rotating torque is 4.9 N·m (0.5 kg-m, 43 in-lb)
or less.
19. Install large end of boot to gear housing assembly.
20. Install small end of boot to inner socket boot mounting groove.
21. Install boot clamp to boot small end.
22. Install large side of boot clamp.
NOTE:
Do not reuse large side of boot clamp.

Tighten large side of boot with boot clamp (stainless wire).

Wrap clamp around boot groove for two turns. Insert a flat-
bladed screwdriver in loops on both ends of wire. Twist 4 to
4.5 turns while pulling them with force of approximately 98 N
(10 kg, 22 lb).

Twist boot clamp as shown. Pay attention to relationship
between winding and twisting directions.
SGIA0465E
Vertical movement of rack 0.265 mm (0.0104 in) or less
Measuring pointRack axial direction 5 mm (0.197 in) from housing end surface
Rack radial direction Axial direction of the adjusting screw
SGIA0550E
Wire length “L” : 370 mm (14.57 in)
SGIA0163E
SGIA0164E

PS-26
POWER STEERING GEAR AND LINKAGE


Twisted point of clamp is in the opposite side of adjusting
screw as shown in the figure (to prevent contact with other
parts).

Bent cut end of the wire toward rack axial as shown in the fig-
ure after twisting the wire 4 to 4.5 turns so that cut end does
not contact with boot.
CAUTION:
Keep gap from cylinder tube 5 mm (0.20 in) or more.
23. Install cylinder tube to gear housing assembly.
24. Adjust inner socket to standard length “L”, and then tighten lock
nut to the specified torque. Refer to PS-18, "
COMPONENT" .
Check length of inner socket “L” again after tightening lock nut.
Make sure that the length is the standard.
CAUTION:
Adjust toe-in after this procedure. Length achieved after
toe-in adjustment is not necessary the above value.
SGIA0214E
SGIA0260J
Inner socket length “L” 169.67 mm (6.68 in)
SGIA0167E

POWER STEERING OIL PUMP
PS-27
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POWER STEERING OIL PUMPPFP:49110
On-Vehicle Inspection and ServiceEGS000AF
OIL PUMP PULLEY HYDRAULIC PRESSURE INSPECTION
Before starting following procedure, check tension of belt.
1. Raise vehicle. Connect oil pressure gauge between oil pump
discharge connector and high pressure hose. Then bleed the
hydraulic circuit.
2. Start engine. Run engine until oil temperature reaches 50°C -
80°C (122 - 176°F).
CAUTION:

Leave valve of hydraulic pressure gauge fully open while
starting and running engine. If engine is started with
valve closed, hydraulic pressure in oil pump goes up.
This will relief pressure along with abnormal increase of
oil temperature.

Care must be taken to keep hose clear of belt and other parts when engine is started.
3. Fully close hydraulic pressure gauge valve with engine at idle. Measure relief pressure.
4. After measurement, open valve slowly.
CAUTION:
Never keep valve closed for 10 seconds or longer.

If relief pressure is outside specification, disassemble and service oil pump. Refer to PS-28, "Disas-
sembly and Assembly(QR20DE and QR25DE Engine Models)" , PS-33, "Disassembly and Assembly
(YD22DDTi Engine Model)" .
5. After inspection, remove oil pressure gauge from hydraulic circuit. Add fluid. Be sure to bleed the system
completely. Refer to PS-6, "
Air Bleeding Hydraulic System" .
Removal and Installation (QR20DE and QR25DE Engine Models)EGS000AG
REMOVAL
1. Loosen adjusting screw and oil pump mounting bolt. Then, remove belt.
2. Remove union bolt and hose for oil pump.
3. Remove oil pump bracket attaching bolt.
4. Remove oil pump from vehicle.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.

After installation, adjust belt tension. Refer to EM-13, "DRIVE BELTS" .

After installation, be sure to bleed system. Refer to PS-6, "Air Bleeding Hydraulic System" . Relief oil pressure
Except YD22DDTi models
: 8,000 - 8,800 kPa (81.60 - 89.76 kg/cm
2 , 1,160 - 1,276 psi)
YD22DDTi models
: 8,500 - 9,300 kpa (98 - 104 kg/cm
2 , 1,390 - 1,480 psi)
SST834-H

PS-28
POWER STEERING OIL PUMP

Disassembly and Assembly(QR20DE and QR25DE Engine Models)EGS000AH
INSPECTION BEFORE DISASSEMBLY
Disassemble the power steering oil pump only if the following items
are found.

Oil leak from any point shown in the figure

Deformed or damaged pulley

Poor performance
DISASSEMBLY
1. Fix power steering pump in a vise.
CAUTION:
When fixing pump in a vise, use aluminum plates to protect steering pump mounting surface.
2. Remove rear bracket mounting bolts. Remove rear bracket from rear body.
3. Remove three front bracket attaching bolts and remove front bracket from casing.
4. Remove four rear body attaching bolts and remove rear body from casing.
5. Remove body seal from casing.
6. Remove side plate (rear) from cartridge. Remove side plate inner and outer seals from side plate (rear).
1. Pulley 2. Front bracket 3. Drive shaft seal
4. Casing 5. Inlet connector seal 6. Inlet connector
7. Flow control valve spring 8. Flow control A valve 9. Dowel pin
10. Flow control B valve assembly 11. Side plate (front) 12. Cartridge
13. Rotor 14. Vane 15. Rotor snap ring
16. Side plate (rear) 17. Side plate inner seal 18. Side plate outer seal
19. Body seal 20. Rear body 21. Rear bracket
SGIA0645E
SST984A