NISSAN X-TRAIL 2003 Service Repair Manual

POWER STEERING GEAR AND LINKAGE
PS-15
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Components EGS0004J
MODEL PR24AD
SGIA0644E

PS-16
POWER STEERING GEAR AND LINKAGE

Disassembly and AssemblyEGS0004K
DISASSEMBLY
1. To disassemble and assemble power steering gear, fix steering
gear mount flange in a vise with copper plates.
CAUTION:

Clean steering gear with kerosene. Be careful to avoid
splashing or applying any kerosene over connector of
discharge port or return port.

Always replace O-rings, oil seals, and copper washes
with new ones.
2. Loosen and remove adjusting screws and lock nuts.
3. Remove rear housing mounting bolts to remove gear sub
assembly.
CAUTION:
Do not disassemble rear housing and pinion gear assem-
bly.
4. Remove tie rod outer socket and boot.
5. Remove spacer ring on lock plate. Move it to rack side to expose
crimping of lock plate.
CAUTION:

Do not reuse boot, spacer ring, and lock plate.

When removing boot, do not damage boot mounting
grooves by tool. If it damaged, it may cause oil leak.
Replace tie rod inner socket and gear housing assembly.

When removing lock plate from rack, avoid damaging
surface of rack. If damaged, rack assembly must be
replaced. Otherwise, oil leaks will result.
6. Raise crimping areas (2) (A) of lock plate. Loosen inner socket
and remove from rack.
1. Gear housing assembly 2. Cylinder tube 3. Rear cover cap
4. Rear housing assembly 5. Pinion seal ring 6. Pinion assembly
7. O ring 8. Lock nut 9. Adjusting screw
10. Spring 11. Retainer 12. Center bushing
13. Rack oil seal (inner) 14. Rack oil seal (outer) 15. Spacer
16. End cover assembly 17. Boot clamp 18. Dust boot
19. Boot band 20. Rack 21. Spacer ring
22. Rack Teflon ring 23. O-ring 24. Lock plate
25. Inner socket 26. Outer socket
SGIA0056E
SGIA0018E
SGIA0019E

POWER STEERING GEAR AND LINKAGE
PS-17
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7. Drill out punch crimping area on cylinder outer rim with a 3 mm
(0.12 in) drill bit [Drill for approx. 1.5 mm (0.059 in) in depth.]
8. Remove end cover with a 36 mm (1.42 in) open head.
CAUTION:
When removing, avoid damaging surface of rack. If dam-
aged, rack assembly must be replaced. Otherwise, oil leaks
will result.
9. Pull rack assembly with rack Teflon ring out of gear housing
assembly.
CAUTION:
When pulling out rack assembly, do not damage cylinder
inner wall. If it damaged, it may cause oil leak. Replace gear
housing assembly.
10. Heat Teflon ring to approx. 40°C (104°F) with a hot air blower Remove it and O-ring from rack. Be careful
not to damage rack.
11. Use a taped 29 mm (1.14 in) socket and an extension bar. Push
out and remove center bushing and rack oil seal together from
gear housing assembly.
CAUTION:

Be careful not to damage gear housing assembly and cyl-
inder inner wall.

If damaged, gear housing assembly must be replaced.
Otherwise, oil leaks will result.
INSPECTION AFTER DISASSEMBLY
Boot
Check boot for tear, wrinkle, and deformation. Replace it, if necessary.
Rack
Check rack gear for damage and wear. Replace it, if necessary.
Gear subassembly

Check pinion gear for damage and wear, and replace if necessary.

Check bearing while rotating it. Replace bearing if bearing ball race was dent, worn, or damaged.
Gear housing cylinder
Check gear housing cylinder for damage and scratch (inner wall). Replace it, if necessary.
Tie rod ball joint
1. Swing torque.
STC0013D
SGIA0461E
SGIA0467E

PS-18
POWER STEERING GEAR AND LINKAGE


Hook spring scale at the position indicated in the figure. Con-
firm the reading at the moment the ball stud begins moving is
within specifications. If the value is outside the standard,
replace outer and inner sockets.
2. Rotating torque

Using a preload gauge (SST), check reading is within range
specified below. If the value is outside the standard, replace
outer and inner sockets.
3. Axial endplay

Apply load of 490 N (50 kg, 110.6 lb) to ball stud axially. Mea-
sure amount of movement that stud makes by using a dial
gauge. Check reading is within range specified below. If not,
replace outer and inner sockets.
ASSEMBLY

Always replace O-rings, oil seals, and copper washers with new ones.
1. Install an O-ring.
CAUTION:
Do not reuse rack Teflon ring and O-ring.
SGIA0152E
Outer socket Inner socket
Oscillating torque [N·m (kg-m, in-lb)]0.30 - 2.94 N·m
(0.03 - 0.30 kg-m, 3 - 26 in-lb)1.0 - 7.8 N·m
(0.10 - 0.80 kg-m, 9 - 69 in-lb)
Measurement on spring balance [N
(kg, lb)]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)
Measuring point Cotter-pin hole of stud Shown as L:106.2 mm (4.18 in)
Outer socket PR24AD
Rotating
torque0.30 - 2.94 N·m (0.03 - 0.30 kg-m, 3 - 26 in-lb)
SGIA0083E
Outer socket : 0.5 mm (0.02 in) or less
Inner socket : 0.2 mm (0.008 in) or less
SGIA0057E

POWER STEERING GEAR AND LINKAGE
PS-19
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2. Heat rack Teflon ring to approximately 40°C (104°F) with dryer.
Assemble it to rack.
3. To fit Teflon ring on rack, install Teflon ring correcting tool (SST)
from tooth side. Compress the rim of ring with the tool. Then, put
the O-ring on the Teflon ring.
4. Insert new rack oil seal.
CAUTION:
Rack oil seal is not reusable. Never reuse rack oil.
a. To avoid damaging inner rack oil seal, wrap an OHP sheet
[approx. 70 mm (2.76 in) × 100 mm (3.94 in)] around rack tooth.
Place oil seal over sheet. Then, pull oil seal along with OHP
sheet until they pass toothed section of rack.
b. Insert rack assembly into gear housing assembly.
CAUTION:
When inserting rack assembly, do not damage cylinder
inner wall. If it damaged, it may cause oil leak. Replace gear
housing assembly.
c. Install center busing and rack oil seal separately.
d. Press rack piston in to move inner rack oil seal to proper posi-
tion.
CAUTION:
Move it until it contacts center bushing.
SST083B
SGIA0464E
SGIA0097E
SST830A

PS-20
POWER STEERING GEAR AND LINKAGE

e. When installing outer rack oil seal, cover end of rack with an
OHP sheet [70 mm (2.76 in) × 100 mm (3.94 in)]. It will avoid
damaging rack oil seal. Then place oil seal over sheet. Pull rack
oil seal along with OHP sheet until they pass rack end. Install
rack oil seal in place using end cover assembly.
f. Attach rack oil seal. Both inner lip and outer lip should face each
other.
5. Using a 36-mm open head, tighten end cover assembly to spec-
ified torque.
CAUTION:
Do not damage rack surface. If it damaged, it may cause oil
leak. Replace rack assembly.
6. After tightening end cover, crimp cylinder at one point as shown
in figure using a punch. This will prevent end cover from getting
loose.
7. Assemble an O-ring to the gear housing.
8. Install gear sub assembly to gear housing.
SGIA0097E
SGIA0058E
: 59 - 74 N·m (6.0 - 7.5 kg-m, 43 - 54 ft-lb)
SST081B
SST073B
SGIA0203E

POWER STEERING GEAR AND LINKAGE
PS-21
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9. Install mounting bolts to rear housing. Tighten them to specified
torque.
10 .
11. Attach lock plate.
CAUTION:
The lock plate is not reusable. Never reuse lock plate.
a. Position spacer ring to rack.
b. Set lock plate to tie rod and inner socket.
c. Apply thread lock adhesive (Three Bond 1324 or equivalent) to
thread of inner socket. Screw inner socket into rack and tighten
to specified torque.
d. Crimp lock plate at two points on rack slit.
e. Install spacer ring to lock plate as shown in the figure.
CAUTION:
When installing spacer ring, avoid scratching it.
12. Decide neutral position of rack gear.
13. Coat the adjusting screw with locking sealant and screw it in.
14. Screw lock nut. Do not tighten lock nut.
15. Tighten adjusting screw to following specified torque.
16. Rotate throughout whole range of pinion so that parts fit with
each other.
17. Install rear cover cap.
18. Install cylinder tube.: 15.7 - 20.5 N·m (1.6 - 2.0 kg·m, 12 - 15 ft-lb)
SGIA0022J
Rack stroke (L) : 66.5 mm (2.618 in)
SST866C
STC0034D
: 4.9 - 5.9 N·m (0.5 - 0.6 kg-m, 44 - 52 in-lb)
: 20 - 26 N·m (2.0 - 2.7 kg-m,14 - 20 ft-lb)
SST742C

PS-22
POWER STEERING GEAR AND LINKAGE

19. Use preload gauge (SST) and torque adapter (SST). Measure
pinion rotation torque within ±180° of neutral position of the gear.
Stop the gear at the point where highest torque is read.
20. Loosen adjusting screw and retighten to 4.9 - 5.9 N·m (0.50 -
0.60 kg-m, 44 - 52 in-lb), and then loosen by 60 - 80°(140-
176°F).
21. With adjusting screw held in place, tighten lock nut to 40 - 58
N·m (4.0 - 6.0 kg-m, 29 - 43 ft-lb).
22. Using a preload gauge (SST), measure rotating torque of pinion
gear. Check that reading is within range specified. If reading is
outside specification, readjust rack. If reading is still outside
specification, replace power steering gear.
23. With tie rod gear installed to gear assembly, turn pinion gear
fully to left.
24. Set dial gauge as shown in figure. Measure vertical movement
of rack when pinion is turned counterclockwise with torque of 4.9
N·m (0.5 kg-m, 43 in-lb). Check reading is within range speci-
fied. If reading is outside of specification, readjust rack. If read-
ing is still outside of specification, replace power steering gear.
25. Position boot band on large-diameter side before installing it.
26. Install small-diameter side of boot to inner socket boot mounting
groove.
27. Install boot band to small-diameter side of boot.
STC0036D
SGIA0098E
Rotational torque of pinion gear : Around neutral position [within ±11.5 mm (0.453 in)]
Average A : 1.67 - 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)
Other than above
Average A : 2.94 N·m (0.30 kg-m, 2 ft-lb)
Maximum variation B : 1.47 N·m (0.15 kg-m, 1 ft-lb)
Specification : 0.08 mm (0.0031 in) or less
SGIA0465E
Measuring point in shown in figure at right.Rack axle direction 5 mm (0.197 in) from housing vertical surface
Rack radial direction Direction of adjusting screw
SGIA0550E

POWER STEERING GEAR AND LINKAGE
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28. Install boot clamp.
a. Tighten large-diameter side of RH/LH boot with boot clamp
(stainless wire).
b. Wrap clamp around boot groove for two turns. Insert screwdriv-
ers in loops on both ends of wire. Twist 4 to 4.5 turns while pull-
ing them with force of approx. 98 N (10 kg, 22.1 lb).
c. Twist boot clamp as shown. Pay attention to relationship
between winding and twisting directions.
d. Twisted point should face front of vehicle with gear installed on
vehicle (to prevent interference with other parts).
e. After twisting wire 4 to 4.5 turns, bend cut end of wire. Cut end of
wire should not touch boot. Be sure wire end is at least 5 mm
(0.20 in) away from clearance for tube.
29. Connect lock nut and outer socket to inner socket. Temporarily
tighten lock nut until length of tie rod is within specification.
CAUTION:
Perform toe-in adjustment after this procedure. Length
achieved after toe-in adjustment is not necessarily value
given here.Wire length ( ): 370 mm (14.57 in)
SST097B
SST440A
SGIA0025E
STC0124D
Tie rod length (L) : 169.67 mm (6.68 in)
STC0125D

PS-24
POWER STEERING OIL PUMP

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 15 seconds or longer.

If relief pressure is outside specification, disassemble and service oil pump. Refer to PS-25, "Disas-
sembly and Assembly(QR20DE and QR25DE engine models)" .
5. After inspection, remove oil pressure gauge from hydraulic circuit. Add fluid. Be sure to bleed the system
completely. Refer to PS-6, "
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, "Bleeding Hydraulic System" . Relief pressure specification:
8,000 - 8,800 kPa (81.4 - 87.3 bar, 83 - 89 kg/cm
2 , 1,180 - 1,266 psi)
SST834-H