transfer NISSAN X-TRAIL 2005 Service Repair Manual

MODEL T30 SERIES
2005 NISSAN EUROPE S.A.S.
All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan
Europe S.A.S., Paris, France.
A GENERAL INFORMATION
B ENGINE
C TRANSMISSION/TRANSAXLE
D DRIVELINE/AXLE
E SUSPENSION F BRAKES
G STEERING H RESTRAINTS
I BODY
J AIR CONDITIONER
K ELECTRICAL
L MAINTENANCE
M INDEXGI General Information
EM Engine Mechanical
LU Engine Lubrication System
CO Engine Cooling System
EC Engine Control System
FL Fuel System
EX Exhaust System
ACC Accelerator Control System
CL Clutch
MT Manual Transaxle
AT Automatic Transaxle
TF Transfer
PR Propeller Shaft
RFD Rear Final Drive
FAX Front Axle
RAX Rear Axle
FSU Front Suspension
RSU Rear Suspension
WT Road Wheels & Tires
BR Brake System
PB Parking Brake System
BRC Brake Control System
PS Power Steering System
SB Seat Belts
SRS Supplemental Restraint System (SRS)
BL Body, Lock & Security System
GW Glasses, Window System & Mirrors
RF Roof
EI Exterior & Interior
IP Instrument Panel
SE Seat
ATC Automatic Air Conditioner
MTC Manual AIr Conditioner
SC Starting & Charging System
LT Lighting System
DI Driver Information System
WW Wiper, Washer & Horn
BCS Body Control System
LAN LAN System
AV Audio Visual, Navigation & Telephone System
ACS Auto Cruise Control System
PG Power Supply, Ground & Circuit Elements
MA Maintenance
IDX Alphabetical Index
QUICK REFERENCE INDEX
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ENGINE ASSEMBLY
EM-85
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Removal and Installation (4WD Models)EBS00KNT
WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:

Always be careful to work safely, avoid forceful or uninstructed operations.

Do not start working until exhaust system and engine coolant are cool enough.

If items or work required are not covered by the engine section, refer to the applicable sections.

Always use the support point specified for lifting.

Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.

For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate front suspension member, and then separate engine and transaxle.
Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. RH engine mounting insulator
4. RH engine mounting bracket 5. Front engine mounting bracket 6. Front engine mounting insulator
7. Center member 8. LH engine mounting insulator 9. LH engine mounting bracket
10. Stopper 11. Grommet
PBIC3830E

ENGINE ASSEMBLY
EM-87
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Use alternator bracket mounting bolt holes for the front side.
2. Lift with hoist and secure engine in appropriate position.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove mounting bolts at front end of center member.
7. Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "
FRONT SUSPENSION ASSEMBLY" .
8. Remove engine, transaxle and transfer assembly with front suspension member and center member from
vehicle downward by carefully operating supporting tools.
CAUTION:

During the operation, make sure that no part interferes with vehicle side.

Before and during this lifting, always check if any harnesses are left connected.

During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.

If necessary, support vehicle by setting a jack or equivalent tool at the rear.Slinger bolts:
Front
: 57.9 N·m (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0271E
KBIA0256E
PBIC2188E
KBIA0270E

EM-90
[QR]
CYLINDER BLOCK

DISASSEMBLY
1. Remove engine, transaxle and transfer (4WD models) assembly from vehicle, and separate transaxle and
transfer (4WD models) assembly from engine. Refer to EM-81, "
ENGINE ASSEMBLY" .
2. Mount engine on an engine stand with the following procedure:
a. Remove oil cooler with oil cooler bracket on right side of cylinder block. Refer to LU-11, "
OIL COOLER" .
b. Install engine sub-attachment (special service tool) to right side
of cylinder block.

Do not use bolt hole at the upper right looking from bolt inser-
tion side as shown in the figure.

Machine a bolt hole at the lower right of the engine sub-
attachment looking from bolt insertion side as shown in the
figure.
c. Lift engine, and mount it onto the engine stand (special service
tool).
PBIC2190E
SBIA0272E
KBIA0140E

EM-192
[YD22DDTi]
OIL SEAL

Removal and Installation of Rear Oil SealEBS01FBO
REMOVAL
1. Remove transaxle and transfer assembly. Refer to MT-19, "Removal and Installation" and TF-57,
"Removal and Installation"
2. Remove clutch cover and disk. Refer to CL-16, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" .
3. Remove flywheel. Refer to EM-231, "
DISASSEMBLY" .
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.

Press in rear oil seal to the position as shown in the figure.

Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.

Avoid inclined fitting. Force fit perpendicularly.
3. Install in the reverse order of removal after this step.
SEM715A
JEM232G

EM-224
[YD22DDTi]
ENGINE ASSEMBLY

Removal
1. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
2. Lift with hoist and secure engine in position.
3. Use the manual lift table caddy (commercial service tool) or
equivalently rigid tool such as a jack or trestle. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove center member.
7. Remove engine and transaxle assembly from vehicle downward by carefully operating supporting tools.
CAUTION:

During the operation, make sure that no part interferes with vehicle side.

Before and during this lifting, always check if any harnesses are left connected.

During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.

If necessary, support vehicle by setting a jack or equivalent tool at the rear.
8. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
9. Separate engine and transaxle and transfer assembly. Refer to MT-19, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.

Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-222, "
ENGINE ASSEMBLY" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.Slinger bolts:
: 33.5 N·m (3.4 kg-m, 25 ft-lb)
SBIA0191E
KBIA0256E
PBIC2188E

ENGINE ASSEMBLY
EM-227
[YD22DDTi]
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REMOVAL
Description of work
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate suspension member, and then separate engine and transaxle.
Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
2. Drain engine coolant from radiator drain plug. Refer to CO-32, "
DRAINING ENGINE COOLANT" .
3. Remove the following parts.

LH and RH engine undercover

LH and RH front wheels

Battery; Refer to SC-4, "BATTERY" .

Drive belts; Refer to EM-141, "Removal and Installation" .

Air duct and air cleaner case assembly; Refer to EM-142, "Removal and Installation" .

Alternator; Refer to SC-17, "Removal and Installation" .

Radiator and cooling fan assembly; Refer to CO-35, "Removal and Installation" and CO-37, "COOL-
ING FAN" .

Charge air cooler; Refer to EM-144, "CHARGE AIR COOLER" .
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all vacuum hoses and air hoses connected to vehicle side at engine side.
Engine room LH
1. Disconnect fuel hose, and plug it to prevent fuel from draining. Refer to EM-146, "INTAKE MANIFOLD" .
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining. Refer to EM-146,
"INTAKE MANIFOLD" .
3. Remove clutch operating cylinder from transaxle, and move it aside. Refer to MT-19, "
TRANSAXLE
ASSEMBLY" and CL-12, "OPERATING CYLINDER" .
4. Disconnect shift cable from transaxle. Refer to MT-16, "
CONTROL LINKAGE" .
Engine room RH
1. Remove engine coolant reservoir tank. Refer to CO-35, "RADIATOR" .
2. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-144, "
Removal and Installation of Compressor" .
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
2. Remove propeller shaft. Refer to PR-4, "
Removal and Installation" .
3. Remove steering shaft from steering gear. Refer to PS-11, "
STEERING COLUMN" .
4. Disconnect power steering fluid cooler piping at a point between body and engine. Refer to PS-37,
"HYDRAULIC LINE" .
5. Remove front wheel sensor (LH and RH) for ABS from brake caliper. Refer to BRC-46, "
WHEEL SEN-
SORS" (ABS), BRC-116, "WHEEL SENSORS" (ESP/TCS/ABS).
6. Remove brake caliper with piping connected from steering knuckle. Temporarily secure it on body with a
rope to avoid load on it. Refer to BR-27, "
FRONT DISC BRAKE" .
7. Remove lower ends of LH and RH strut from steering knuckle. Refer to FSU-5, "
FRONT SUSPENSION
ASSEMBLY" .
8. Preparation for the separation work of transaxle as follows:
a. Remove crankshaft position sensor from transmission. Refer toEM-157, "
OIL PAN AND OIL STRAINER" .
b. Remove transaxle joint bolts which pierce at oil pan lower rear side. Refer to EM-157, "
OIL PAN AND OIL
STRAINER" .

EM-228
[YD22DDTi]
ENGINE ASSEMBLY

Removal
1. Install engine slingers into front right of cylinder head and rear
left of cylinder head.
2. Lift with hoist and secure engine in position.
3. Use the manual lift table caddy (commercial service tool) or
equivalently rigid tool such as a jack or trestle. Securely support
bottom of engine and transaxle, and simultaneously adjust hoist
tension.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
4. Remove RH engine mounting insulator.
5. Pull LH engine mounting through-bolt out.
6. Remove mounting bolts at front end of center member.
7. Remove front suspension member mounting bolts and nuts.
Refer to FSU-5, "
FRONT SUSPENSION ASSEMBLY" .
8. Remove engine, transaxle and transfer assembly with suspension member and center member from vehi-
cle downward by carefully operating supporting tools.
CAUTION:

During the operation, make sure that no part interferes with body side.

Before and during this lifting, always check if any harnesses are left connected.

During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.

If necessary, support vehicle by setting a jack or equivalent tool at the rear.Slinger bolts:
: 33.5 N·m (3.4 kg-m, 25 ft-lb)
SBIA0191E
KBIA0256E
PBIC2188E
KBIA0270E

ENGINE ASSEMBLY
EM-229
[YD22DDTi]
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9. Remove power steering oil pump with piping connected from engine. Move it aside on suspension mem-
ber. Refer to PS-37, "
HYDRAULIC LINE" .
10. Remove front engine mounting and rear engine mounting through-bolts to remove suspension member.
11. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
12. Separate engine and transaxle and transfer assembly. Refer to MT-19, "
TRANSAXLE ASSEMBLY" .
INSTALLATION
Install in the reverse order of removal.

Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-222, "
ENGINE ASSEMBLY" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .

Before starting engine, bleed air from fuel piping. Refer to FL-18, "Air Bleeding" .

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.

Bleed air from lines and hoses of applicable lines, such as in cooling system.

After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —

CYLINDER BLOCK
EM-231
[YD22DDTi]
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DISASSEMBLY
1. Remove engine, transaxle and transfer assembly from the vehicle, then separate engine and transaxle
and transfer assembly. Refer to EM-222, "
ENGINE ASSEMBLY" .
2. Remove clutch cover and disk. Refer to CL-16, "
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" .
3. Install engine to engine stand as follows:
a. Remove flywheel.
b. Secure ring gear with the ring gear stopper (special service
tool), then loosen mounting bolts with TORX socket (size: T55,
Commercial Service Tools) and remove them. As an alternative
method hold crankshaft pulley with the pulley holder (special
service tool: KV10109300) to remove flywheel.
CAUTION:

Do not disassemble flywheel.

Do not place flywheel with signal plate facing down.

When handling signal plate, take care not to damage or
scratch it.

Handle signal plate in a manner that prevents it from
becoming magnetized.
c. Install the engine sub-attachment (special service tool) to the
rear side of cylinder block.

Align knock pins on cylinder block with pin holes on attach-
ment to install.
NOTE:
Installation bolts are part of engine sub-attachment.
d. Install the engine stand shaft (special service tool).
NOTE:
Use commercially available M12 (0.47 in) mounting bolts and
nuts (4 sets) with strength grade of 9T (minimum).
1. Rear oil seal retainer 2. Cylinder block 3. Oil pressure switch
4. Fuel pump bracket 5. Oil level gauge guide 6. Top ring
7. Second ring 8. Oil ring 9. Oil jet
10. Piston pin 11. Snap ring 12. Piston
13. Main bearing upper 14. Thrust bearing 15. Connecting rod
16. Key 17. Connecting rod bearing 18. Connecting rod cap
19. Connecting rod nut 20. Main bearing lower 21. Crankshaft
22. Main bearing cap bolt 23. Main bearing cap 24. Pilot bushing
25. Flywheel 26. Washer 27. Oil jet relief valve
28. Drain plug 29. Rear oil seal
PBIC2406E
JEM192G