NISSAN X-TRAIL 2003 Electronic Repair Manual

ESP OFF SWITCH
BRC-123
[ESP/TCS/ABS]
C
D
E
G
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MA
B
BRC
ESP OFF SWITCHPFP:25145
Removal and InstallationEFS001CQ
REMOVAL
1. Remove the instrument lower driver panel. Refer toIP-7,
"INSTRUMENT LOWER DRIVER PANEL".
2. Push the ESP OFF switch's pawls and remove the switch from
the instrument lower driver panel.
INSTALLATION
Installation is the reverse order of removal.
SFIA0390E

BRC-124
[ESP/TCS/ABS]
ESP OFF SWITCH

CL-1
CLUTCH
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
A
B
CL
CLUTCH
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tool ......................................... 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
CLUTCH PEDAL ........................................................ 5
On-vehicle Inspection and Adjustment ..................... 5
HEIGHT ADJUSTMENT ....................................... 5
CLUTCH SWITCH POSITION ADJUSTMENT ..... 5
FREE PLAY INSPECTION .................................... 6
CLEARANCE CHECK ........................................... 6
Removal and Installation .......................................... 6
INSPECTION AFTER REMOVAL ......................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ......................................................... 10
OPERATING CYLINDER ...........................................11Removal and Installation ........................................ 11
REMOVAL ........................................................... 11
INSTALLATION ................................................... 11
Disassembly and Assembly .................................... 11
DISASSEMBLY ................................................... 11
INSPECTION AFTER DISASSEMBLY ................ 11
ASSEMBLY ......................................................... 11
CLUTCH PIPING ....................................................... 12
Removal and Installation ........................................ 12
CLUTCH RELEASE MECHANISM ........................... 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSPECTION AFTER REMOVEL ....................... 13
INSTALLATION ................................................... 13
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 15
Removal and Installation ........................................ 15
REMOBAL ........................................................... 15
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 17
Clutch Control System ............................................ 17
Clutch Master Cylinder ........................................... 17
Clutch Operating Cylinder ...................................... 17
Clutch Disk ............................................................. 17
Clutch Cover ........................................................... 17
Clutch Pedal ........................................................... 17

CL-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
CautionECS004JW
lRecommended fluid is brake fluid “DOT 3”or“DOT4”.
lNever reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.
lWhen removing and installing clutch piping, use Tool.
lUse new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
lNever use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WAR NIN G:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
SBR686C

PREPARATION
CL-3
D
E
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MA
B
CL
PREPARATIONPFP:00002
Special Service ToolsECS004JX
Commercial Service ToolECS004JY
To o l n a m e
Tool numberDescription
Pin punch
ST23550000
Tip diameter: 4.5 mm (0.177 in) dia.Removing and installing master cylinder
spring pin
Drift
KV30101400
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.Installing clutch release bearing
Diaphragm adjusting wrench
ST20050240Adjusting unevenness of diaphragm spring
of clutch cover
Clutch aligning bar
KV30101600 (New)
KV30100100 (Former)
a: 22.8 mm (0.898 in) dia.
b: 15.7 mm (0.618 in) dia.
c: 12.0 mm (0.472 in)Installing clutch disc
(QR20DE)
Clutch aligning bar
ST20630000
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.077 in)Installing clutch cover and disc
(YD22DDTi)
ZZA0515D
ZZA0838D
ZZA0508D
ZZA0505D
S-NT405
Tool nameDescription
1. Flare nut crowfoot
2. Torque wrench
a: 10 mm (0.39 in)Removing and installing clutch piping
S-NT360

CL-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartECS004JZ
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-5CL-8CL-9CL-11
Refer to EM section.EM-61
,EM-184
CL-13CL-15CL-15CL-15CL-15CL-15CL-15CL-15CL-15CL-16CL-16CL-16CL-16
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutchdoesnotdisengage 1234 55555 5667

CLUTCH PEDAL
CL-5
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B
CL
CLUTCH PEDALPFP:46540
On-vehicle Inspection and AdjustmentECS0 01 W B
HEIGHT ADJUSTMENT
1. Check that clutch pedal height H1from upper surface of the
dash panel is within the specified range.
2. If pedal height H
1is outside the specification, loosen stopper
bolt lock nut B and turn stopper bolt to adjust.
3. When pedal height comes into the specified range, tighten stop-
per bolt lock nut B to the specified torque.
4. Confirm that when the clutch is disengaged, free play A (at the
pedal pad's top surface) and pedal height H
2, are within the
range shown below:
5. Check that free play A, at the top surface of the pedal pad, and
the pedal height H
2are outside the specification, loosen lock
nut A and turn push rod to adjust.
CAUTION:
Threaded end of the push rod must be positioned inside the
clevis.
6. Tighten lock nut A to the specified torque.
CLUTCH SWITCH POSITION ADJUSTMENT
lAdjust the clutch switch position until, with the clutch pedal
depressed, the clearance between the stopper rubber and
threaded end of the clutch switch is within the range specified as
clearance C. Tighten lock nut D.Pedal height H
1: 161 - 171 mm (6.34 - 6.73 in)
Lock nut B
:16-21N·m(1.6-2.2kg·m,12-15ft·lb)
A: Pedal free play at the pedal pad:
9 - 16 mm (0.35 - 0.63 in)
[Looseness at clevis pin: 1.0 - 3.0 mm (0.04 - 0.12in)]
Pedal height H
2with the clutch disengaged:
QR20DE: 86.1 mm (3.390 in) or more
YD22DDTi: 81.9 mm (3.224 in) or more
MAA0474DSCIA0809E
Lock nut A
: 7.8 - 11.8 N·m (0.8 - 1.2 kg·m,69 - 104 in·lb)
SCIA0810E
Clearance C : 0.1 - 1.0 mm (0.004 - 0.039 in)
Lock nut D
:12-14N·m(1.2-1.5kg·m,9-10ft·lb)
SCIA0823E

CL-6
CLUTCH PEDAL
FREE PLAY INSPECTION
lPress the clutch pedal by hand until certain resistance can be
felt. Using a scale, check that the free play is within the specified
range.
CLEARANCE CHECK
1. Start the engine and let it idle.
2. Apply parking brake.
3. Depress the brake pedal.
4. Fully depress clutch pedal and shift to 1st gear.
5. Release clutch pedal gradually. Stop releasing the pedal at the
point where the clutch is about to be engaged. Using a scale,
check the clearance between the clutch pedal and floor panel to
see if it is within the specified range.
NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point.Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify they the inspection.
Removal and InstallationECS001WC
NOTE:
Install clutch pedal assembly and adjust the pedal height. Tighten stopper bolt to the specified torque.Pedalfreeplay :9-16mm(0.35-0.63in)
MAA0023D
Pedal height when the clutch disengages:
85 mm (0.335 in) or more
MAA0024D
SCIA0337E
1 Pedal bracket assembly 2 Fulcrum pin 3 Clutch switch
4 Stopper bolt 5 Lock nut 6 Bushing
7 Bushing 8 Snap pin 9 Stopper rubber
10 Clutch pedal 11 Bushing 12 Clevis pin
13 Stopper rubber 14 Bushing 15 Assist spring

CLUTCH PEDAL
CL-7
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INSPECTION AFTER REMOVAL
lCheck clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal.
lCheck assist spring for settling. If settling is found, replace the assist spring.

CL-8
CLUTCH FLUID
CLUTCH FLUID
PFP:00017
Air Bleeding ProcedureECS001WD
CAUTION:
lMonitor fluid level in the reservoir to make sure it does not empty.
lDo not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
lBleed the operating cylinder.
1. Fill the master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to the air bleeder.
3. Depress the clutch pedal slowly and fully a few times at an inter-
val of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder.
5. Close air bleeder.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
Air bleeder
: 5.9 - 9.8 N·m (0.6 - 1.0kg·m,52 -86 in·lb)
SCIA0327E