2003 NISSAN X-TRAIL Electronic Repair Manual

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Page 1001 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CLUTCH MASTER CYLINDER
CL-9
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CLUTCH MASTER CYLINDERPFP:30610
Removal and InstallationECS00353
REMOVAL
1. Using one of the following methods, remove hose from the nipple.
lDrai

Page 1002 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CL-10
CLUTCH MASTER CYLINDER
Disassembly and Assembly
ECS00354
DISASSEMBLY
1. Using a pin punch, remove spring pin, nipple and seal from the
cylinder body.
2. Loosen push rod lock nut. Remove clevis a

Page 1003 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual OPERATING CYLINDER
CL-11
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OPERATING CYLINDERPFP:30620
Removal and InstallationECS00355
REMOVAL
1. Drainclutchfluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. I

Page 1004 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CL-12
CLUTCH PIPING
CLUTCH PIPING
PFP:30650
Removal and InstallationECS0 01 W I
Carefully observe the following steps during clutch tube removal and installation.
lDo not spill clutch fluid onto paint

Page 1005 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CLUTCH RELEASE MECHANISM
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CLUTCH RELEASE MECHANISMPFP:30502
Removal and InstallationECS001WJ
REMOVAL
1. Remove manual transaxle from the vehicle. Refer toMT-16, "Removal

Page 1006 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CL-14
CLUTCH RELEASE MECHANISM
1. Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfa

Page 1007 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
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CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS0 01 W K
CAUTION:
Be careful not to bring any grease i

Page 1008 of 3066

NISSAN X-TRAIL 2003 Electronic Repair Manual CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Clutch cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using

CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Clutch cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (special service tool).
lCheck clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
lWorn thrust ring will generate a beating noise when tapped at
therivetwithahammer.
lBroken thrust ring will make a clinking sound when cover is
shaken up and down.
lIf a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disk contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.
Flywheel runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1. Apply recommended Grease to clutch disk and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
2. Install clutch disk and clutch cover. Pre-tighten mounting bolts
and install clutch aligning bar.
3. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
4. Install manual transaxle. Refer toMT-16, "
Removal and Installation"
Tolerance for diaphragm spring lever unevenness:
0.7 mm (0.028 in)
SCL466-C
Allowable flywheel runout:
Vehicles with QR20DE:EM-89, "
Flywheel Deflec-
tion"
Vehicles with
YD22DDTi:EM-208, "Flywheel Deflec-
tion"
AEM100
Engine type Tool number
QR20DE KV30100100
YD22DDTi ST20630000
Tightening torque:
First step : 9.9 - 19 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
Final step : 35 - 44 N·m (3.5 - 4.5 kg·m, 26 - 32 ft·lb)SCIA0909E

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