2003 NISSAN X-TRAIL air bleeding

FUEL FILTER
FL-17
[YD22DDTi]
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FUEL FILTERPFP:16400
Removal and InstallationEBS00BLA
REMOVAL
1. Remove air duct, air cleaner case and mass air flow sensor assembly. Refer to EM-133, "AIR CLEANER
AND AIR DUCT" .
2. Remove fuel filter protector.
3. Disconnect fuel hoses at fuel filter bracket.
CAUTION:
Plug the pipe to prevent fuel from draining.
4. Remove fuel filter with fuel filter bracket.
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
5. Using band-type fuel filter wrench (commercial service tool),
remove fuel filter.
6. Turn fuel filter upside down to drain fuel.
7. Remove drain plug from fuel filter.
INSTALLATION
Note the following, and install in the reverse order of removal.

Replace O-ring on drain plug with new one.

Screw the fuel filter by hand until packing contacts sealing surface of bracket. Then tighten it by turning
approximately 2/3 turn.

After installation, bleed air from fuel line. Refer to FL-18, "Air Bleeding" .
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.

Start the engine and rev it up and make sure there is no fuel leakage at connections.
PBIC2501E
SBIA0135E
SBIA0136E
Drain plug
: 4.9 N·m (0.5 kg-m, 43 in-lb)

FL-18
[YD22DDTi]
FUEL FILTER

Air BleedingEBS00BLB
After fuel filter is replaced and after fuel system components are
removed/installed, bleed air from fuel line as follows:

Move priming pump up and down to bleed air from fuel path.

When air is bled, pumping of priming pump becomes heavy stop
operation at that time.

Crank engine until it starts. Do not crank engine for more than
30 seconds.

If engine does not start, stop cranking and repeat step 1 above.

If engine does not operate smoothly after it has started, race it
two or three times.

If air cannot be bled easily (pumping of priming pump does not
become heavy), disconnect feed-side of hose between fuel filter and electronically controlled fuel pump.
After that, operate priming pump and confirm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel FilterEBS00MRU
1. Prepare a tray at the drain hose open end.
2. Loosen drain cock, and operate priming pump to drain water
from fuel filter.
CAUTION:

Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.

Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. After draining, close drain cock by hand.
CAUTION:
If drain cock is tightened excessively, it may be damaged
and fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer to FL-18, "
Air Bleeding" .
5. Start engine and make sure there is no fuel leakage.
SBIA0137E
SBIA0138E

CL-1
CLUTCH
C TRANSMISSION/TRANSAXLE
CONTENTS
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SECTION
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CLUTCH
PRECAUTIONS .......................................................... 2
Caution ..................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
CLUTCH ................................................................ 4
CLUTCH PEDAL ........................................................ 5
On-Vehicle Inspection and Adjustment .................... 5
Removal and Installation .......................................... 6
INSPECTION AFTER REMOVAL ......................... 6
CLUTCH FLUID .......................................................... 7
Air Bleeding Procedure ............................................ 7
CLUTCH MASTER CYLINDER .................................. 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 9
Disassembly and Assembly ..................................... 9
DISASSEMBLY ..................................................... 9
INSPECTION AFTER DISASSEMBLY ................. 9
ASSEMBLY ........................................................... 9
OPERATING CYLINDER .......................................... 10
Removal and Installation ........................................ 10REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Disassembly and Assembly .................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ................ 10
ASSEMBLY ......................................................... 10
CLUTCH PIPING ....................................................... 11
Removal and Installation ........................................ 11
CLUTCH RELEASE MECHANISM ........................... 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL ... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 15
INSTALLATION ................................................... 16
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 17
Clutch Control System ............................................ 17
Clutch Master Cylinder ........................................... 17
Clutch Operating Cylinder ...................................... 17
Clutch Disc ............................................................. 17
Clutch Cover ........................................................... 17

CLUTCH PEDAL
CL-5
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CLUTCH PEDALPFP:46540
On-Vehicle Inspection and AdjustmentECS001WB
1. Check to see if clevis pin floats freely in bore of clutch pedal. It
should not be bound by clevis or clutch pedal.
a. If clevis pin is not free, check that pedal stopper bolt is not apply-
ing pressure to clutch pedal causing clevis pin to bind. To adjust,
loosen lock nut and turn pedal stopper bolt.
b. Tighten lock not.
c. Verify that clevis pin floats in bore of clutch pedal. It should not
be bound by clutch pedal.
d. If clevis pin is still not free, remove clevis pin and check for
deformation or damage. Replace clevis pin if necessary. Leave
clevis pin removed for step 2.
2. Check clutch pedal stroke for free range of movement.
a. With clevis pin removed, manually move clutch pedal up and
down to determine if it moves freely.
b. If any sticking is noted, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
and re-verifity that clevis pin floats freely in bore of clutch pedal.
3. Check clutch hydraulic and system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever, clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding noted, repair or replace related parts as necessary.
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-7, "
Air Bleeding
Procedure" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
PCIB0814E

CLUTCH FLUID
CL-7
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CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS008B9
CAUTION:

Monitor clutch fluid level in reservoir tank to make sure it
does not empty.

Do not spill clutch fluid onto painted surfaces. If it spills,
wipe up immediately and wash the affected area with water.

Bleed the air of operating cylinder.
1. Fill master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it.
4. With clutch pedal depressed, open air bleeder valve.
5. Close air bleeder valve.
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in the
clutch fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-10,
"Removal and Installation" .
SCIA1098E
SCL839

CLUTCH MASTER CYLINDER
CL-9
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Drain clutch fluid from reservoir tank and remove hose.

Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Using a flare nut torque wrench, remove clutch tube.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. First remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehi-
cle.
INSTALLATION
1. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
2. Install master cylinder assembly and tighten mounting nut to the specified torque. Refer to CL-8,
"Removal and Installation" .
3. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Refer to CL-11,
"Removal and Installation" .
4. Attach clevis of clevis pin to clutch pedal.
5. Attach snap pin to clevis pin.
6. Install hose to nipple.
7. After completing this procedure, inspect and adjust pedal height and then bleed clutch tube. Refer to CL-
5, "On-Vehicle Inspection and Adjustment" , CL-7, "Air Bleeding Procedure"
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin, nipple and seal from cylinder body using a
pin punch.
2. Loosen push rod lock nut. Remove clevis and lock nut.
3. Remove seat.
4. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to reduce possibility of the pis-
ton popping out.
5. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole

Damaged or deformed nipple or reservoir tank

Settling of spring

Cracked or deformed seat
ASSEMBLY
1. Apply rubber lubricant to internal surface of cylinder body, sliding surface of piston assembly, and piston
cup. Insert piston assembly and return spring.
2. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down push rod by
hand to prevent piston assembly from popping out.
3. Install seat.
4. Install clevis to push rod and tighten lock nut to the specified torque. Refer to CL-8, "
Removal and Installa-
tion" .
5. Install seal and nipple to cylinder body. Install spring pin, using a pin punch.
PCIB0274E

CL-10
OPERATING CYLINDER

OPERATING CYLINDERPFP:30620
Removal and InstallationECS008BC
REMOVAL
1. Drain clutch fluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Remove clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolt and remove operating cylinder from vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.

Install hose with care so that it will not be bent or twisted.

After completing the procedure, bleed clutch tube. Refer to CL-7, "Air Bleeding Procedure" .
Disassembly and AssemblyECS008BD
DISASSEMBLY

Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.

Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole

Settling of the spring

Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and install push rod and dust cover.
1. Air bleeder valve 2. Copper washer 3. Union bolt
4. Clutch hose 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston assembly 9. Piston cup
10. Piston spring
PCIB0765E

CLUTCH PIPING
CL-11
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CLUTCH PIPINGPFP:30650
Removal and InstallationECS008BE
Carefully observe the following steps during clutch tube removal and installation.

Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.

To fix clutch hose on the bracket, position clutch hose clasp on
the bracket locating emboss and drive lock plate vertically from
above. Be careful not to bend or twist clutch hose. Do not
scratch or damage clutch hose.

Tighten clutch tube flare nut to the specified torque. Refer to CL-
11 , "Removal and Installation" .

Tighten clutch hose union bolt to the specified torque. Refer to
CL-11, "
Removal and Installation" .
CAUTION:
Do not reuse the copper washer.

After installation, bleed clutch tube. Refer to CL-7, "Air Bleeding
Procedure" .
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder 5. Clutch pedal 6. Master cylinder
PCIB0813E
PCIB0812E