2005 NISSAN X-TRAIL air bleeding

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

CLUTCH PEDAL
CL-5
D
E
F
G
H
I
J
K
L
MA
B
CL

CLUTCH PEDALPFP:46540
On-Vehicle Inspection and AdjustmentECS001WB
1. Make sure that 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, make sure that pedal stopper bolt or
ASCD clutch switch is not applying pressure to clutch pedal
causing clevis pin to bind. To adjust, loosen lock nut and turn
pedal stopper bolt or ASCD clutch switch.
b. Tighten lock not.
c. Make sure 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 found, replace related parts (clutch pedal
bracket, assist spring, bushing etc.). Reassemble clutch pedal
and again make sure 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 is found, repair or replace related parts as necessary.
b. If hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-8, "
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.
PCIB0876E

CL-8
CLUTCH FLUID

CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS008B9
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.
CAUTION:

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

Keep painted surface on the body or other parts free of
clutch fluid. 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 to release
air.
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 clutch
fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-12,
"Components" .
SCIA1098E
SCL839

CL-10
CLUTCH MASTER CYLINDER

Removal and InstallationECS008BA
REMOVAL
1. Using one of the following methods, remove hose from nipple.

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:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch tube using a flare nut torque wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. Remove mounting nuts on master cylinder assembly, and then master cylinder assembly from vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque. Refer to CL-9, "
Components" .
4. Tighten clutch tube flare nut to the specified torque using a flare
nut torque wrench. Refer to CL-13, "
Removal and Installation" .
5. Set clevis to clutch pedal and insert clevis pin.
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch
hydraulic system. Refer to CL-5, "
On-Vehicle Inspection and Adjustment" and CL-8, "Air Bleeding Proce-
dure" .
Disassembly and AssemblyECS008BB
DISASSEMBLY
1. Remove spring pin using a pin punch.
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove seat from cylinder body.
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly
popping out.
6. 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 return spring

Cracked or deformed seatLength “L”
RHD models : 125.5 mm (4.80 in)
LHD models : 122.0 mm (4.94 in)
SCIA5158E
PCIB0274E

CLUTCH PIPING
CL-13
D
E
F
G
H
I
J
K
L
MA
B
CL

CLUTCH PIPINGPFP:30650
Removal and InstallationECS008BE
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

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

Tighten clutch tube flare nut to the specified torque.

Tighten clutch hose union bolt to the specified torque.
CAUTION:
Do not reuse copper washer.

After installation, bleed the air from the clutch hydraulic system.
Refer to CL-8, "
Air Bleeding Procedure" .
1. Clutch tube 2. Lock plate 3. Clutch hose
4. Operating cylinder 5. Clutch pedal 6. Master cylinder
PCIB0813E
PCIB0681E

BR-1
BRAKE SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BR
A
B
BR

BRAKE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Brake System .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
BRAKE PEDAL .......................................................... 6
On-Vehicle Inspection and Adjustment .................... 6
Components ............................................................. 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
BRAKE FLUID ............................................................ 8
Checking Brake Fluid Level ..................................... 8
Checking Brake Line ................................................ 8
Changing Brake Fluid ............................................... 8
Bleeding Brake System ............................................ 9
BRAKE PIPING AND HOSE .................................... 10
Hydraulic Piping ..................................................... 10
Removal and Installation of Front Brake Piping and
Brake Hose ............................................................. 11
REMOVAL ............................................................ 11
INSTALLATION ................................................... 12
Removal and Installation of Rear Brake Piping and
Brake Hose ............................................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Inspection ............................................................... 13
BRAKE MASTER CYLINDER .................................. 14
Components ........................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14INSTALLATION ................................................... 14
Disassembly and Assembly .................................... 15
MODELS WITHOUT ESP (PISTON STOPPER
APPLIED.) ........................................................... 15
MODELS WITHOUT ESP (PISTON STOPPER
NOT APPLIED.) .................................................. 17
MODELS WITH ESP ........................................... 19
BRAKE BOOSTER ................................................... 23
On-Vehicle Inspection and Service ......................... 23
FUNCTION INSPECTION ................................... 23
AIRTIGHTNESS INSPECTION ........................... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
VACUUM LINES ....................................................... 25
Removal and Installation ........................................ 25
Inspection ............................................................... 26
VISUAL INSPECTION ......................................... 26
CHECK VALVE INSPECTION ............................. 26
FRONT DISC BRAKE ............................................... 27
Component ............................................................. 27
Inspection ............................................................... 27
PAD THICKNESS ................................................ 27
Pad Replacement ................................................... 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 28
Caliper Removal and Installation ............................ 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 29
Caliper Disassembly and Assembly ....................... 29
DISASSEMBLY ................................................... 29
INSPECTION AFTER DISASSEMBLY ................ 29
DISC ROTOR INSPECTION ............................... 30
ASSEMBLY ......................................................... 30
BRAKE BURNISHING PROCEDURE ................. 31
REAR DISC BRAKE ................................................. 32
Component ............................................................. 32
Inspection ............................................................... 32
PAD WEAR INSPECTION ................................... 32

BRAKE FLUID
BR-9
C
D
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H
I
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K
L
MA
B
BR

4. Be sure there is no foreign material in reservoir tank. Refill with
new brake fluid.
5. Connect a vinyl tube to bleed valve.
6. Rest foot on brake pedal. Loosen bleed valve. Slowly depress
pedal until it stops. Tighten bleed valve. Release brake pedal.
Repeat this process a few times at 2-3 second intervals until
new brake fluid flows out.
For bleeding procedure. Refer to BR-9, "
Bleeding Brake Sys-
tem" .
Bleeding Brake SystemEFS000C4
CAUTION:

Carefully monitor brake fluid level at master cylinder during bleeding operation.

Fill reservoir with new brake fluid “DOT 3” or “DOT 4”. Make sure it is full at all times while bleed-
ing air out of system.

Place a container under master cylinder to avoid spillage of brake fluid.

While bleeding, pay attention to master cylinder fluid level.

For models with ABS, turn ignition switch OFF and disconnect ABS actuator connectors or bat-
tery ground cable.

Bleed air in the following order.
Right rear brake, left front brake, left rear brake, right front brake
1. Turn OFF ignition switch. Remove ABS actuator connector.
2. Connect a vinyl tube to bleed valve.
3. Fully depress the brake pedal 4 to 5 times.
4. With brake pedal depressed, loosen air bleeder and bleed air.
5. Close bleed valve.
6. Slowly release brake pedal.
7. Tighten bleed valve to the specified torque.
8. Repeat steps 2 - 7. Occasionally refill master cylinder reservoir tank. Be sure to keep it at least half-full.
BRA0006D
: 6.9 - 8.8 N·m (0.7 - 0.9 kg-m, 61- 78 in-lb)

BR-24
BRAKE BOOSTER

INSPECTION AFTER REMOVAL
Output rod length inspection
1. Using a handy vacuum pump, apply a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) to the brake
booster.
2. Check output rod length.
3.
INSTALLATION
1. Loosen lock nut to adjust input rod length so that length “B” (in
the figure) satisfies the specified value.
2. After adjusting “B”, temporarily tighten lock nut to install booster
assembly to vehicle.
3. Connect brake pedal to input rod clevis.
4. Connect brake pedal assembly mounting nuts and tighten to the
specified torque.
5. Connect master cylinder to booster assembly.
6. Adjust brake pedal height and play.
7. Tighten input rod lock nut to the specified torque.
8. Bleed air. Refer to BR-9, "
Bleeding Brake System" . Reference value at vacuum of –66.7 kPa (–500 mmHg,
–19.69 inHg):
Without ESP models : 10.4 mm (0.409 in)
With ESP models : -6.2 mm (-0.244 in)
SBR208E
Length “B” standard : 125 mm (4.92 in)
SGIA0060E