NISSAN X-TRAIL 2005 Service Repair Manual

FUEL TANK
FL-25
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
FL

INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start engine and rev it up and make sure there is no fuel leakage at connections.

FL-26
[YD22DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00BL5
Tightening TorqueEBS00BL6
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)* Fuel tank capacity
Approx. 60 (13-1/4 Imp gal)
Fuel recommendationRefer to GI-5
Fuel filter drain plug4.9 (0.50, 43)*
Fuel tank band31.4 (3.2, 23)
Fuel filler tube 9.1 (0.93, 81)*
Vent tube9.1 (0.93, 81)*
Lock ring32.9 (3.4, 24)
Fuel transport pump4.8 (0.49, 42)*

ACC-1
ACCELERATOR CONTROL SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION ACC
A
ACC

ACCELERATOR CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEM ...................... 2
Removal and Installation .......................................... 2
REMOVAL ............................................................. 2
INSTALLATION ..................................................... 2
INSPECTION AFTER INSTALLATION ................. 2SERVICE DATA AND SPECIFICATIONS (SDS) ........ 3
Tightening Torque ..................................................... 3

ACC-2
ACCELERATOR CONTROL SYSTEM

ACCELERATOR CONTROL SYSTEMPFP:18005
Removal and InstallationEBS00KP5
REMOVAL
1. Disconnect accelerator pedal position sensor harness connector.
2. Loosen nuts, and remove accelerator pedal assembly.
CAUTION:

Do not disassemble accelerator pedal assembly. Do not remove accelerator pedal position sen-
sor from accelerator pedal assembly.

Avoid impact from dropping etc. during handling.

Be careful to keep accelerator pedal assembly away from water.

Do not adjust adjusting screw (painted white).
INSTALLATION
Installation is the reverse order of removal.
INSPECTION AFTER INSTALLATION

Make sure that accelerator pedal moves smoothly within the whole operation range.

Make sure that accelerator pedal securely returns to the original position.

For the electrical inspection of accelerator pedal position sensor, refer to EC-409, "DTC P2122, P2123
APP SENSOR" (QR20DE and QR25DE) or EC-1099, "DTC P0122, P0123 APP SENSOR" (YD22DDTi).
CAUTION:
When the harness connector of the accelerator pedal position sensor is disconnected, perform
“Accelerator Pedal Released Position Learning”. (QR20DE and QR25DE) Refer to EC-46, "
Acceler-
ator Pedal Released Position Learning" (WITH EURO-OBD) or EC-559, "Accelerator Pedal
Released Position Learning" (WITHOUT EURO-OBD).
NOTE:
In the case of YD22DDTi, it is unnecessary to perform “Accelerator Pedal Released Position Learning”
even when disconnecting the harness connector of the accelerator pedal position sensor.
1. Accelerator pedal assembly
PBIC2412E

SERVICE DATA AND SPECIFICATIONS (SDS)
ACC-3
C
D
E
F
G
H
I
J
K
L
MA
ACC

SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Tightening TorqueEBS00KP6
Unit: N·m (kg-m, in-lb)
Accelerator pedal assembly 5.1 (0.52, 45)

ACC-4
SERVICE DATA AND SPECIFICATIONS (SDS)

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

CLUTCH
PRECAUTIONS .......................................................... 2
Service Notice or Precautions .................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
CLUTCH PEDAL ........................................................ 5
On-Vehicle Inspection and Adjustment .................... 5
Removal and Installation .......................................... 6
COMPONENTS .................................................... 6
REMOVAL ............................................................. 6
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Components ............................................................. 9
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY .......................................................... 11
OPERATING CYLINDER .......................................... 12
Components ........................................................... 12Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Disassembly and Assembly .................................... 12
DISASSEMBLY ................................................... 12
INSPECTION AFTER DISASSEMBLY ................ 12
ASSEMBLY ......................................................... 12
CLUTCH PIPING ....................................................... 13
Removal and Installation ........................................ 13
CLUTCH RELEASE MECHANISM ........................... 14
Removal and Installation ........................................ 14
COMPONENTS ................................................... 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 15
INSTALLATION ................................................... 15
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL ... 16
Removal and Installation ........................................ 16
COMPONENTS ................................................... 16
REMOVAL ........................................................... 16
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 17
INSTALLATION ................................................... 18
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 19
Clutch Control System ............................................ 19
Clutch Master Cylinder ........................................... 19
Clutch Operating Cylinder ...................................... 19
Clutch Disc ............................................................. 19
Clutch Cover ........................................................... 19

CL-2
PRECAUTIONS

PRECAUTIONSPFP:00001
Service Notice or PrecautionsECS004JW

Recommended clutch fluid is brake fluid “DOT 3" or “DOT 4". Refer to MA-17, "Fluids and Lubricants" .

Do not reuse drained clutch fluid.

Be careful not to splash clutch fluid on painted areas.

When removing and installing clutch piping, use Tool.

Use new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.

Do not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.Tool number : GG94310000 or Commercial equivalent
PCIB0272E

PREPARATION
CL-3
D
E
F
G
H
I
J
K
L
MA
B
CL

PREPARATIONPFP:00002
Special Service ToolsECS008B7
Commercial Service ToolsECS00CRA
Tool number
Tool nameDescription
ST20050240
Diaphragm adjusting wrenchAdjusting unevenness of diaphragm spring of
clutch cover
KV30101600
Clutch aligning bar
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in) dia.Installing clutch cover and clutch disc
(For QR engine models)
KV30100100
Clutch aligning bar
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.Installing clutch cover and clutch disc
(For YD engine models)
ZZA0508D
S-NT405
ZZA1178D
Tool nameDescription
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.Removing and installing master cylinder
spring pin
GG94310000
Flare nut torque wrench
a: 10 mm (0.39 in)Removing and installing clutch piping
ZZA0515D
S-NT406

CL-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartECS008B8
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-12
EM-81
(QR engine models), EM-222
(YD engine models)
CL-14
CL-16
EM-116
(QR engine models),EM-255
(YD engine models)
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and 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
Clutch does not disengage 1 2 3 4 5 5 5 5 5 5 6 6 7