transmission oil NISSAN X-TRAIL 2003 Service Repair Manual

GI-4
PRECAUTIONS

General PrecautionsEAS000FQ

Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.

Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.

When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.

Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.

If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.

To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.

Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.

Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.

Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.

Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.

Replace inner and outer races of tapered roller bearings and needle bearings as a set.

Arrange the disassembled parts in accordance with their assembled locations and sequence.

Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.

After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.

Use only the fluids and lubricants specified in this manual.
SGI285
SGI231
SEF289H
SGI233

PRECAUTIONS
GI-5
C
D
E
F
G
H
I
J
K
L
MB
GI


Use approved bonding agent, sealants or their equivalents when required.

Use tools and recommended special tools where specified for safe and efficient service repairs.

When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4 × 4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4 × 4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.

Remove the propeller shaft.

Use free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.

Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.

When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.

Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000P9
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.

Above –7°C (20°F) ... Summer type diesel fuel.

Below –7°C (20°F) ... Winter type diesel fuel.
SGI234

EM-26
[QR]
OIL PAN AND OIL STRAINER

b. Insert seal cutter (special service tool) between oil pan (upper)
and oil pan (lower).
CAUTION:
Be careful not to damage the mating surface.
c. Slide seal cutter by tapping on the side of the tool with a ham-
mer.
4. Remove oil strainer.
5. Remove oil pan (upper) with the following procedure:
a. Remove drive belt. Refer to EM-13, "
DRIVE BELTS" .
b. Remove A/C compressor with piping connected. And locate it aside temporarily with ropes or equivalent
not to disturb the following work. Refer to ATC-144, "
Removal and Installation of Compressor" .
c. Remove oil level gauge guide.
d. Remove exhaust front tube and its support. Refer to EX-2, "
EXHAUST SYSTEM" .
e. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger, and then remove center member.
Refer to EM-78, "
ENGINE ASSEMBLY" .
f. Remove rear plate cover, and four transaxle joint bolts. Refer to MT-17, "
TRANSAXLE ASSEMBLY" (M/T
models) or AT- 4 1 3 , "
REMOVAL AND INSTALLATION" (A/T models).
g. Loosen bolts in reverse order as shown in the figure.
NOTE:
Disregard No.12 and 17 when loosening.
SEM365EA
KBIA2024J
PBIC0257E
SBIA0233E

EM-148
[YD22DDTi]
OIL PAN AND OIL STRAINER

a. Insert the Seal cutter (special service tool) between oil pan
upper and oil pan lower.
CAUTION:

Be careful not to damage aluminum mating surface.

Do not insert screwdriver, or oil pan flange will be
deformed.
b. Slide the Seal cutter by tapping on the side of the Seal cutter
with a hammer.
c. Remove oil pan lower.
5. Remove A/C compressor belt. Refer to EM-131, "
Tension Adjustment" .
6. Remove A/C compressor and bracket. Refer to ATC-144, "
Removal and Installation of Compressor" .
7. Remove front exhaust tube and its support. Refer to EX-2, "
EXHAUST SYSTEM" .
8. Remove crankshaft position sensor from transaxle.
CAUTION:

Avoid impacts such as a dropping.

Do not disassemble.

Keep it away from metal particles.

Do not place sensor close to magnetic materials.
9. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger. Refer to EM-208, "
Removal and
Installation" .
10. Remove center member. Refer to EM-208, "
ENGINE ASSEM-
BLY" .
11. Remove rear plate cover and transaxle joint bolts.
12. Remove catalyst and catalyst rear diffuser. Refer to EM-139,
"Removal and Installation" .
SEM544G
SEM545G
PBIC2277E
JEM553G

EM-214
[YD22DDTi]
CYLINDER BLOCK

e. Hoist engine and install it to the engine stand (special service
tool).
NOTE:
It is possible to set engine sub-attachment and engine stand
shaft to the engine stand at first, then install engine later.

Widely use engine stand can be used.
NOTE:
The figure shows an example of general-purpose engine
stand that can hold mating surface of transmission with drive
plate and rear plate removed.
5. Drain engine oil and engine coolant from inside engine. Refer to LU-21, "
Changing Engine Oil" .
6. Drain engine coolant by removing drain plug from inside of
engine.
7. Remove the following parts and related parts. (Only major parts are listed.)

Intake manifold (Refer to EM-136, "Removal and Installation" .)

Exhaust manifold and turbocharger (Refer to EM-141, "Removal and Installation" .)

Rocker cover (Refer to EM-168, "Removal and Installation" .)

Fuel injector (Refer to EM-157, "Removal and Installation" .)

Oil pan and oil strainer (Refer to EM-147, "Removal and Installation" .)

Water pump (Refer to CO-42, "WATER PUMP" .)

Thermostat and water piping (Refer to CO-44, "THERMOSTAT AND WATER PIPING" .)
JEM193G
PBIC0085E
PBIC2439E

EC-888
[YD (WITH EURO-OBD)]
ENGINE CONTROL SYSTEM

Crankcase Ventilation SystemEBS01170
DESCRIPTION
In this system, blow-by gas is sucked into the air duct after oil separation by oil separator in the rocker cover.
INSPECTION
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any hose
cannot be freed of obstructions, replace.
CAN CommunicationEBS01171
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.
PBIB0590E
SEC692

ENGINE CONTROL SYSTEM
EC-1219
[YD (WITHOUT EURO-OBD)]
C
D
E
F
G
H
I
J
K
L
MA
EC

Crankcase Ventilation SystemEBS011X4
DESCRIPTION
In this system, blow-by gas is sucked into the air duct after oil separation by oil separator in the rocker cover.
INSPECTION
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any hose
cannot be freed of obstructions, replace.
CAN CommunicationEBS011X5
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.
PBIB0590E
SEC692

MT-1
MANUAL TRANSAXLE
C TRANSMISSION/TRANSAXLE
CONTENTS
D
E
F
G
H
I
J
K
L
M
SECTION
A
B
MT

MANUAL TRANSAXLE
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 6
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 8
NVH Troubleshooting Chart ..................................... 8
MANUAL TRANSAXLE ......................................... 8
DESCRIPTION ............................................................ 9
Cross-Sectional View ............................................... 9
DOUBLE-CONE SYNCHRONIZER .................... 10
TRIPLE-CONE SYNCHRONIZER ...................... 10
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) ................. 10
M/T OIL ......................................................................11
Changing M/T Oil .................................................... 11
DRAINING ............................................................ 11
FILLING ................................................................ 11
Checking M/T Oil ..................................................... 11
OIL LEAKAGE AND OIL LEVEL .......................... 11
SIDE OIL SEAL ........................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
POSITION SWITCH .................................................. 13
Checking ................................................................ 13
BACK-UP LAMP SWITCH .................................. 13
PARK/NEUTRAL POSITION SWITCH ............... 13
CONTROL LINKAGE ............................................... 14
Components of Control Device and Cable ............. 14
Removal and Installation ........................................ 15
AIR BREATHER HOSE ............................................ 16
Removal and Installation ........................................ 16
TRANSAXLE ASSEMBLY ........................................ 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
Component Parts (RS5F51A) ................................ 19CASE AND HOUSING COMPONENTS .............. 19
GEAR COMPONENTS ....................................... 20
SHIFT CONTROL COMPONENTS ..................... 22
FINAL DRIVE COMPONENTS ........................... 23
Component Parts (RS6F51A) ................................. 24
CASE AND HOUSING COMPONENTS .............. 24
GEAR COMPONENTS ....................................... 25
SHIFT CONTROL COMPONENTS ..................... 27
FINAL DRIVE COMPONENTS ........................... 28
Disassembly and Assembly (RS5F51A) ................. 28
DISASSEMBLY ................................................... 28
ASSEMBLY ......................................................... 32
Disassembly and Assembly (RS6F51A) ................. 37
DISASSEMBLY ................................................... 37
ASSEMBLY ......................................................... 41
Adjustment (RS5F51A) ........................................... 47
INPUT SHAFT END PLAY .................................. 47
MAINSHAFT END PLAY ..................................... 48
DIFFERENTIAL SIDE BEARING PRELOAD ...... 48
REVERSE IDLER GEAR END PLAY .................. 49
Adjustment (RS6F51A) ........................................... 50
INPUT SHAFT END PLAY .................................. 50
MAINSHAFT END PLAY ..................................... 51
DIFFERENTIAL SIDE BEARING PRELOAD ...... 52
REVERSE IDLER GEAR END PLAY .................. 53
INPUT SHAFT AND GEARS .................................... 54
Assembly and Disassembly (RS5F51A) ................. 54
DISASSEMBLY ................................................... 54
INSPECTION AFTER DISASSEMBLY ................ 55
ASSEMBLY ......................................................... 57
Assembly and Disassembly (RS6F51A) ................. 61
DISASSEMBLY ................................................... 61
INSPECTION AFTER DISASSEMBLY ................ 62
ASSEMBLY ......................................................... 64
MAINSHAFT AND GEARS ....................................... 68
Assembly and Disassembly (RS5F51A) ................. 68
DISASSEMBLY ................................................... 68
INSPECTION AFTER DISASSEMBLY ................ 69

OVERALL SYSTEM
AT-23
D
E
F
G
H
I
J
K
L
MA
B
AT

CLUTCH AND BAND CHART

*1: Operates when overdrive control switch is set in “OFF” position.

*2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not con-
tract because oil pressure area on the “release” side is greater than that on the “apply” side.

*3: Oil pressure is applied to 4th “apply” side in condition *2 above, and brake band contracts.

*4: A/T will not shift to 4th when overdrive control switch is set in “OFF” position.

: Operates.

A: Operates when throttle opening is less than 3/16, activating engine brake.

B: Operates during “progressive” acceleration.

C: Operates but does not affect power transmission.

D: Operates when throttle opening is less than 3/16, but does not affect engine brake. Shift positionRever
se
clutch
5High
clutch
6For-
ward
clutch
15Over-
run
clutch
17Band servo
Forward
one-way
clutch
16Low
one-
way
clutch
18Low &
revers
e
brake
19Lock-
upRemarks
2nd
apply3rd
releas
e4th
apply
PPA R K
POSITION
RREVERSE
POSITION
NNEUTRAL
POSITION
D*41st *1D B B
Automatic
shift
1 ⇔ 2 ⇔ 3 ⇔
4 2nd *1A B
3rd *1A *2C C B
*1
4th C *3C C
21stBB
Automatic
shift
1 ⇔ 2⇐3 2ndB
3rd *2C C B
11stB
Locks (held
stationary) in
1st speed
1 ⇐ 2⇐3 2ndB
3rd *2C C B

AT-36
OVERALL SYSTEM

CONTROL OF SHIFT SOLENOID VALVES A AND B
The TCM activates shift solenoid valves A and B according to sig-
nals from the throttle position sensor and revolution sensor to select
the optimum gear position on the basis of the shift schedule memo-
rized in the TCM.
The shift solenoid valve performs simple ON-OFF operation. When
set to “ON”, the drain circuit closes and pilot pressure is applied to
the shift valve.
RELATION BETWEEN SHIFT SOLENOID VALVES A AND B GEAR POSITIONS
CONTROL OF SHIFT VALVES A AND B
Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift
valves A and B.
The drawing above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure
applied to the end face of the shift valve overcomes spring force, moving the valve upward.
Lock-up ControlECS00CTE
The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip to
increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from
the TCM. The signal is converted to an oil pressure signal which controls the torque converter clutch piston.
CONDITIONS FOR LOCK-UP OPERATION
When vehicle is driven in 3rd and 4th gear position, vehicle speed and throttle opening are detected. If the
detected values fall within the lock-up zone memorized in the TCM, lock-up is performed.
SAT008J
Shift solenoid valveGear position
D1 , 21 , 11D2 , 22 , 12D3D4 (OD) N-P
A ON (Closed) OFF (Open) OFF (Open) ON (Closed) ON (Closed)
B ON (Closed) ON (Closed) OFF (Open) OFF (Open) ON (Closed)
SAT009J
Overdrive control switch ON OFF
Selector lever “D” position
Gear position D
4D3
Vehicle speed sensor More than set value
Throttle position sensor Less than set opening
Closed throttle position switch OFF
A/T fluid temperature sensor More than 40°C (104°F)