NISSAN X-TRAIL 2003 Service Repair Manual

PREPARATION
TF-5
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PREPARATIONPFP:00002
Special Service ToolsEDS0004P
Tool number
Tool nameDescription
KV38101700
Drift
a: 82 mm (3.23 in) dia.
b: 78 mm (3.07 in) dia.Installing side oil seal (installing adapter case
oil seal)
ST3127S000
Preload gaugeMeasuring preload torque
ST33220000
Drift
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.Removing drive pinion
KV381054S0
Puller

Removing pinion rear bearing outer race

Removing pinion front bearing outer race

Removing gear ring oil seal
ST30031000
ReplacerRemoving pinion front bearing inner race
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

Removing gear ring bearing inner race
(adapter case side)

Installing companion flange
ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.Removing gear ring bearing inner race
(transfer case side)
ZZA1149D
ZZA0503D
ZZA1046D
ZZA0601D
ZZA0700D
ZZA1002D
ZZA0810D

TF-6
PREPARATION

ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Installing gear ring bearing outer race
(transfer case side)

Installing gear ring bearing inner race
(transfer case side)

Installing gear ring bearing inner race
(adapter case side)

Installing gear ring bearing outer race
(adapter case side)

Installing transfer case oil seal
KV40101840
Drift
a: 77 mm (3.03 in) dia.
b: 85 mm (3.35 in) dia.Installing gear ring bearing outer race
(transfer case side)
ST33230000
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.Installing gear ring oil seal
ST27863000
Drift
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.Installing gear ring bearing inner race
(transfer case side)
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Installing gear ring bearing inner race
(transfer case side)
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.Installing gear ring bearing inner race
(adapter case side)
KV40105230
Drift
a: 92 mm (3.62 in) dia.
b: 86 mm (3.39 in) dia.Installing gear ring bearing outer race
(adapter case side) Tool number
Tool nameDescription
ZZA0811D
ZZA0881D
ZZA1046D
ZZA1003D
ZZA1003D
ZZA1003D
ZZA1141D

PREPARATION
TF-7
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KV38100300
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.Installing pinion rear bearing outer race
ST33400001
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.

Installing pinion front bearing outer race

Installing pinion sleeve oil seal
ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.

Installing pinion front bearing outer race

Installing pinion front bearing inner race Tool number
Tool nameDescription
ZZA1046D
ZZA0814D
ZZA0978D

TF-8
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS001V9
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 pageTF-9TF-57TF-57TF-57TF-66TF-66
SUSPECTED PARTS
(Possible cause)
TRANSFER OIL (Level low)
TRANSFER OIL (Wrong)
TRANSFER OIL (Level too high)
LIQUID GASKET (Damaged)
O-RING (Worn or damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
SymptomNoise 1 2 3 3
Transfer oil leakage 3 1 2 2 2

TRANSFER OIL
TF-9
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TRANSFER OILPFP:KLD30
ReplacementEDS001W2
DRAINING
CAUTION:
When draining oil, protect exhaust tube with cover.
1. Run the vehicle to warm up the transfer body sufficiently.
2. Stop engine, and remove drain plug to drain transfer oil.
3. Apply sealant to drain plug. Install drain plug on transfer and
tighten to the specified torque. Refer to TF-57, "
COMPO-
NENTS" .
FILLING
1. Remove filler plug and add gear oil until oil level reaches the
specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the oil. (Fill up for approx. 3 minutes)
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Apply recommended sealant to filler plug. Install filler plug on
transfer and tighten to the specified torque. Refer to TF-57, "
COMPONENTS" .
InspectionEDS001W3
OIL LEAKAGE AND OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
2. Before installing filler plug, apply sealant. Install filler plug on
transfer and tighten to the specified torque. Refer to TF-57,
"COMPONENTS" .
SDIA0512E
Oil grade and Viscosity
: Refer to MA-17, "
Fluids and Lubricants" .
Oil capacity
: Approx. 0.31 (1/2 lmp pt)
SDIA0513E
SDIA0513E

TF-10
ALL MODE 4X4 SYSTEM

ALL MODE 4X4 SYSTEMPFP:47850
Power Transfer DiagramEDS001VA
System DescriptionEDS001VB
ELECTRIC CONTROLLED COUPLING
Operation Principle
1. The 4WD control unit supplies command current to electric con-
trolled coupling (4WD solenoid).
2. The control clutch is engaged by electromagnet and torque is
detected in control clutch.
3. The cam operates in response to control clutch torque and
applies pressure to main clutch.
4. The main clutch transmits torque to front wheels according to
pressing power.

Transmission torque to the rear wheels is determined accord-
ing to command current.
4WD CONTROL UNIT

4WD controls distribution of drive power between front-wheel
drive (100:0) and 4WD (50:50) conditions according to signals
from sensors.

Self-diagnosis can be done with CONSULT-II.
SDIA1607E
SFIA0284E
SDIA1844E
SDIA2285E

ALL MODE 4X4 SYSTEM
TF-11
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4WD MODE SWITCH
AUTO Mode

Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.

4WD mode makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.

On roads which do not require 4WD, AUTO mode contributes to improved fuel economy by driving in con-
ditions close to front-wheel drive.

Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by dis-
tributing optimum torque to rear wheels.
LOCK Mode

Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.

Vehicle will switch automatically to AUTO mode if vehicle speed increases. If vehicle speed then
decreases, the vehicle automatically returns to direct 4-wheel driving conditions.

LOCK mode will change to AUTO mode automatically, when the vehicle speed exceeds approx. 30 km/h
(19 MPH). The LOCK indicator light keeps illuminating.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
LOCK mode may be prohibited, or speeds at which LOCK mode is enabled may be restricted detecting tire
conditions.
2WD Mode
Vehicle is in front-wheel drive.
NOTE:

If front wheels are slipping in 2WD mode, do not switch to AUTO or LOCK. This can cause difficulties for
the system.

Even if the 4WD mode switch is in 2WD mode, the 4WD control unit occasionally automatically change to
AUTO mode depending on the driving condition (For example; Depressing the acceleration firmly). This is
not malfunction. However, 4WD indicator lamp dose not illuminate.
4WD INDICATOR LAMP AND LOCK INDICATOR LAMP
The following is the indications of indicator lamp.
4WD WARNING LAMP
Turns ON when there is a malfunction in 4WD system. It indicates that the vehicle is in fail-safe mode and
change to front-wheel drive or shifting driving force-4WD (Rear-wheels still have some driving torque).
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1
seconds after the engine starts if system is normal.
4WD Warning Lamp Indication
Condition 4WD indicator lamp LOCK indicator lamp
AUTO mode ON OFF
LOCK mode ON ON
2WD mode OFF OFF
Lamp check Turns ON for approx. 1 second when ignition switch is turned ON.
SDIA2298E
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON. Turns OFF
approx. 1 seconds after engine start.
4WD system malfunctionON
Protection function is activated due to heavy load to electric con-
trolled coupling. (4WD system is not malfunctioning and 4WD system
changes to 2WD mode.)Rapid flashing: 2 times/second
(Flashing in approx. 1 minute and then turning OFF.)

TF-12
ALL MODE 4X4 SYSTEM

System DiagramEDS001VC
Large difference in diameter of front/rear tiresSlow flashing: 1 time/2 seconds
(Continuing to flash until turning ignition switch OFF)
Other than above (system normal) OFFCondition 4WD warning lamp
SDIA1866E

ALL MODE 4X4 SYSTEM
TF-13
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COMPONENTS FUNCTION DESCRIPTION
CAN CommunicationEDS0027K
SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
CAN COMMUNICATION UNIT (M/T MODELS WITHOUT ESP)
System diagram
Component parts Function
4WD control unit

Controls driving force distribution by signals from each sensor and switch from front wheel driving
mode (100:0) to 4WD mode (50:50).

2WD mode is available by fail-safe function if malfunction is detected in electrical system.
Wheel sensors Detects wheel speed.
4WD solenoid Controls electric controlled coupling by operation signal from 4WD control unit.
Electric controlled coupling Transmits driving force to rear final drive.
4WD mode switch Able to select from 2WD, AUTO or LOCK mode.
4WD warning lamp

Illuminates if malfunction is detected in electrical system of 4WD system.

There is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.

There are 2 blinks in 1 second if load is still applied to driving parts.
4WD indicator lamp Indicate operation with optimal distribution of torque to front/rear wheels.
LOCK indicator lamp Indicate that 4WD system is under direct 4-wheel driving mode.
ABS actuator and electric unit
(control unit) (without ESP) or
ESP/TCS/ABS control unit (with
ESP)Transmits the following signals via CAN communication to 4WD control unit.

Vehicle speed signal

Stop lamp switch signal (brake signal)
ECMTransmits the following signals via CAN communication to 4WD control unit.

Accelerator pedal position signal

Engine speed signal
Unified meter control unit Transmits conditions of parking brake switch via CAN communication to 4WD control unit.
PKIA6458E

TF-14
ALL MODE 4X4 SYSTEM

Input/output signal chart
T: Transmit R: Receive
CAN COMMUNICATION UNIT (A/T MODELS WITHOUT ESP)
System diagram
Input/output signal chart
T: Transmit R: Receive Signals ECMABS actuator and
electric unit
(control unit)4WD control unit Combination meter
Stop lamp switch signal T R
Engine speed signal T R R
Engine coolant temperature signal T R
Accelerator pedal position signal T R
A/C compressor feedback signal T R
Vehicle speed signalTRR
RT
ABS warning lamp signal T R
4WD warning lamp signalTR
4WD mode indicator lamp signal T R
Parking brake switch signalRT
MI signal T R
PKIA6457E
Signals ECM TCMABS actuator
and electric unit
(control unit)4WD control
unitCombination
meter
Stop lamp switch signalRT
TR
P·N range signal R T
A/T position indicator lamp signal T R
Overdrive control switch signal R T
O/D OFF indicator signal T R
Closed throttle position signal T R
Wide open throttle position signal T R