Product Detail Manual CL

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C TRANSMISSION/TRANSAXLE

SECTION

CL

CLUTCH

A

B

CL

D

E

CONTENTS
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 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 .......................................... 7
COMPONENTS .................................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 7
CLUTCH FLUID .......................................................... 8
Air Bleeding Procedure ............................................ 8
CLUTCH MASTER CYLINDER .................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9

Revision: June 2006

CSC (CONCENTRIC SLAVE CYLINDER) ................ 11
Removal and Installation ........................................ 11
REMOVAL ........................................................... 11
INSTALLATION ................................................... 11
CLUTCH PIPING ....................................................... 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 13
Removal and Installation ........................................ 13
COMPONENTS ................................................... 13
REMOVAL ........................................................... 13
INSPECTION AND ADJUSTMENT AFTER
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Clutch Control System ............................................ 16
Clutch Pedal ........................................................... 16
Clutch Disc ............................................................. 16
Clutch Cover ........................................................... 16

CL-1

F

G

H

I

J

K

L

M

2007 Versa

PRECAUTIONS
PRECAUTIONS
PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”

ECS00GVW

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.
WARNING:
●
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
●
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
●
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.

Service Notice or Precautions

ECS00FST

Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-11,
"RECOMMENDED FLUIDS AND LUBRICANTS".
●
Never reuse fluid drained from clutch system.
●
Be careful not to splash brake fluid on painted areas.
●
Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.
●
Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic
system.
●
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylinder). Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage CSC seal and may cause clutch fluid leakage.
●
Do not disassemble clutch master cylinder and CSC.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.
●

Revision: June 2006

CL-2

2007 Versa

PREPARATION
PREPARATION
Special Service Tools

PFP:00002

A
ECS00FSU

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Description
Tool number
(Kent-Moore No.)
Tool name

B

Adjusting unevenness of diaphragm spring of
clutch cover

ST20050240
( — )
Diaphragm spring adjusting wrench

CL

D
ZZA0508D

E

Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
b: 19.8 mm (0.780 in) dia.

KV30101000
( — )
Clutch aligning bar

F

ZZA1178D

G

Commercial Service Tools

ECS00G57

Tool name

Description

Power tool

Loosening bolts and nuts

H

I

J

PBIC0190E

K

L

M

Revision: June 2006

CL-3

2007 Versa

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

PFP:00003
ECS00FSV

EM-103
FLYWHEEL (Distortion)

2

PRESSURE PLATE (Distortion)

2

DIAPHRAGM SPRING (Out of tip alignment)

2

DIAPHRAGM SPRING (Damaged)

2

CLUTCH DISC (Lack of spline grease)

CLUTCH DISC (Hardened)

CL-13
CLUTCH DISC (Dirty or burned)

2

4

5

2

1

Clutch noisy

1

Clutch slips

1

Clutch does not disengage

1

Revision: June 2006

CLUTCH DISC (Worn out)

Symptom

2

CLUTCH DISC (Oily)

Clutch pedal spongy

CLUTCH DISC (Lining broken)

CL-11
CSC (Concentric slave cylinder) (Worn, dirty or damaged)

1

CLUTCH DISC (Runout is excessive)

EM-73
ENGINE MOUNTING (Loose)

Clutch grabs/chatters

CLUTCH DISC (Out of true)

CL-8
CLUTCH LINE (Air in line)

SUSPECTED PARTS (Possible cause)

CL-5

Reference page

CLUTCH PEDAL (Inspection and adjustment)

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

2

5

CL-4

5

5

5

5

3
5

6

6

7

2007 Versa

CLUTCH PEDAL
CLUTCH PEDAL
On-vehicle Inspection and Adjustment
1.
a.

b.
c.
d.
2.
a.
b.
3.

PFP:46540

A
ECS00GVX

Check to see if the master cylinder rod end floats freely. It
should not be bound by the clutch pedal.
B
If the rod end is not free, check that the ASCD switch is not
applying pressure to the clutch pedal causing the rod end to
bind. To adjust, disconnect the ASCD switch electrical connector
CL
and turn the ASCD switch.
Connect the ASCD switch electrical connector.
Verify that the master cylinder rod end floats freely. It should not
D
be bound by the clutch pedal.
If the rod end is still not free, remove the rod end and check for
PCIB1491E
deformation or damage. Leave the rod end removed for step 2.
E
Check the clutch pedal stroke for free range of movement.
With the master cylinder rod end removed, manually move the pedal up and down to determine if it moves
freely.
F
If any sticking is noted, replace the clutch pedal assembly. Re-verify that the master cylinder rod end floats
freely.
Adjust clutch interlock switch (1) position so that clearance
G
between clutch pedal (2) and thread end of clutch interlock
switch (1), with clutch pedal fully depressed, is within specification (C).
H
Clearance C
: 0.74 - 1.96 mm (0.0291 - 0.0772 in)
I

J

K

L

M
WCIA0594E

Revision: June 2006

CL-5

2007 Versa

CLUTCH PEDAL
4.

Adjust ASCD clutch switch (1) position so that clearance
between clutch pedal (2) and thread end of ASCD clutch switch
(1), with clutch pedal fully released, is within specification (A).
Clearance A

: 0.74 - 1.96 mm (0.0291 - 0.0772 in)

WCIA0595E

5.
a.
b.

Check the clutch hydraulic system components (clutch master cylinder, clutch operating cylinder, clutch
withdrawal lever and clutch release bearing) for sticking or binding.
If any sticking or binding is noted, repair or replace the related parts as necessary.
If any 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 of the air from the system.

Revision: June 2006

CL-6

2007 Versa

CLUTCH PEDAL
Removal and Installation

ECS00FSX

A

COMPONENTS

B

CL

D

E

F

G

H

I
WCIA0596E

1.

Clutch pedal assembly

2.

Lock nut

4.

ASCD clutch switch

5.

Lock nut

3.

Clutch interlock switch

J

REMOVAL
1.
2.
3.
4.
5.

Remove instrument lower finisher. Refer to IP-11, "Removal and Installation" .
Disconnect clutch interlock switch and ASCD clutch switch harness connectors.
Remove clutch switch harness clamp from clutch pedal assembly.
Disconnect master cylinder rod end from clutch pedal lever.
Remove clutch pedal assembly nuts, and then remove clutch
pedal assembly.

K

L

M

PCIB1491E

INSPECTION AFTER REMOVAL
Check clutch pedal for bend, damage or a cracked weld. If bend, damage or a cracked weld is found, replace
clutch pedal assembly.

INSTALLATION
Installation is in the reverse order of removal.
●
After installing the clutch switches, adjust the switch positions. Refer to CL-5, "On-vehicle Inspection and
Adjustment" .

Revision: June 2006

CL-7

2007 Versa

CLUTCH FLUID
CLUTCH FLUID
Air Bleeding Procedure

PFP:00017
ECS00FSY

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:
●
Carefully monitor fluid level in reservoir tank during bleeding operation.
●
Keep painted surface of body and other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
●
First bleed the air from the operating cylinder air bleed
valve (1) and then from the bleed connector air bleed valve.
1. Connect a transparent vinyl tube and container to the air bleeder
valve on the clutch operating cylinder.
2. Fill reservoir tank with new clutch fluid.
3. Depress and release the clutch pedal slowly and fully 15 times
at an interval of 2 to 3 seconds.
4. With pedal depressed, continue the bleeding procedure.
PCIB1494E

5.

Push the lock pin (1) of the bleeding connector (2) into the
locked position.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding connector (2) when fluid pressure is applied in the tube.

PCIB1495E

6.

Slide clutch tube (1) in the direction of the arrow as shown, then
bleed the air from the tube.
Dimension A

7.
8.
9.

: 5 mm (0.20 in)

Return clutch tube (1) and lock pin (2) to their original positions.
Release clutch pedal and wait for 5 seconds.
Repeat steps 2 to 8 until no bubbles are observed in the clutch
fluid.

PCIB1496E

Revision: June 2006

CL-8

2007 Versa

CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
Removal and Installation

PFP:30610

A
ECS00FSZ

REMOVAL
1.

2.

Use one of the following methods to remove hose from master cylinder.
B
● Drain clutch fluid from reservoir tank and remove hose.
● Remove hose from master cylinder. Immediately plug hose and reservoir tank to prevent clutch fluid
from dripping.
CL
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immediately and wash the affected area with water.
D
Remove master cylinder rod end from clutch pedal assembly.
E

F

G
PCIB1491E

3.

Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).

H

I

J

PCIB1497E

4.

INSTALLATION
1.

2.

K

Rotate master cylinder clockwise by 45° and remove from the vehicle.
L

Tilt master cylinder clockwise by 45° and insert it in the mounting
hole. Rotate counterclockwise to secure it. At this time, nipple is
in the up position.
Install master cylinder rod end to clutch pedal.

M

SCIA1286E

Revision: June 2006

CL-9

2007 Versa

CLUTCH MASTER CYLINDER
3.
4.
5.
6.

Install clutch tube (1) fully into connector of master cylinder (2).
Install lock pin (3) fully into connector of master cylinder (2).
Fill with new clutch fluid and bleed air from the system. Refer to
CL-8, "CLUTCH FLUID" .
After completing this procedure, inspect and adjust the clutch
pedal. Refer to CL-5, "On-vehicle Inspection and Adjustment" .

PCIB1500E

Revision: June 2006

CL-10

2007 Versa

CSC (CONCENTRIC SLAVE CYLINDER)
CSC (CONCENTRIC SLAVE CYLINDER)
Removal and Installation

PFP:30500

A
ECS00FT0

CAUTION:
●
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin- B
der). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.
●
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi- CL
ately and wash the affected area with water.

REMOVAL
1.
2.

Remove transaxle assembly. Refer to MT-15, "Removal and Installation" .
Remove CSC bolts and the CSC from clutch housing.

D

E

F

G
PCIB1498E

INSTALLATION
1.

2.
3.

Install CSC to clutch housing and then tighten bolts to specification. Refer to MT-17, "Case and Housing
Components" .
CAUTION:
● Do not reuse CSC.
● Do not insert and operate CSC because piston and stopper of CSC components may fall off.
Install transaxle assembly. Refer to MT-15, "Removal and Installation" .
Bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .

H

I

J

K

L

M

Revision: June 2006

CL-11

2007 Versa

CLUTCH PIPING
CLUTCH PIPING
Removal and Installation

PFP:30650
ECS00FT1

PCIB1499E

1.

Clutch tube

2.

Lock pin

3.

CSC

4.

Clutch damper

5.

Master cylinder

6.

Clutch pedal

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

REMOVAL
1.
2.
3.

Remove lock pin (2) from clutch damper (3).
Remove clutch tube (1) from clutch damper (3).
Remove clutch damper (3) from bracket (4).

WCIA0597E

INSTALLATION
Installation is in the reverse order of removal.
●
Make sure that all tubes are fully installed into connectors.
●
Make sure that all connector lock pins are fully installed.
●
After installation, bleed the air from the clutch hydraulic system. Refer to CL-8, "Air Bleeding Procedure" .

Revision: June 2006

CL-12

2007 Versa

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and Installation

PFP:30100

A
ECS00FT2

COMPONENTS
B

CL

D

E

F

G
WCIA0637E

1.

Flywheel

2.

Clutch disc *1, *2

3.

Clutch cover

H

Apply lithium-based grease including molybdenum disulphide.
*1.

Do not clean in solvent.

*2.

When installing, be careful that grease applied to input shaft does not adhere to
clutch disc.

CAUTION:
●
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylinder). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc
sliding parts may damage CSC seal and may cause clutch fluid leakage.
●
Be careful not to apply any grease to the clutch disc facing, pressure plate surface and flywheel
surface.

I

J

K

REMOVAL
1.
2.

Remove transaxle assembly from the vehicle. Refer to MT-15, "Removal and Installation" .
Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.

L

INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
●

Check clutch disc for backlash of spline and runout of facing.
Maximum backlash of spline
(at outer edge of disc)
Distance of runout check point
(from hub center)

●
●

M

: 1.0 mm (0.039 in)
: 215 mm (8.46 in)

Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
Measure backlash to clutch disc spline and input shaft spline at
the circumference of clutch disc. If outside the specification,
replace clutch disc.
Maximum allowable spline backlash

Revision: June 2006

SCL221

: 1.0 mm (0.039 in)

CL-13

2007 Versa

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
●

Use a suitable tool to measure the depth to clutch disc facing
rivet heads. If it exceeds the allowable wear limit, replace clutch
disc.
Wear limit of facing
surface to rivet head

: 0.3 mm (0.012 in)

SCL229

Clutch Cover
Check clutch cover installed on vehicle for unevenness of diaphragm
spring toe height.
Uneven limit
Tool number A
●
●

●

: 0.7 mm (0.028 in) or less
: ST20050240 (

—

)

If out of limit, adjust the height using Tool (A).
Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
NOTE:
● Worn thrust ring will generate a beating noise when tapped at
PCIB1502E
the rivet with a suitable tool.
● Broken thrust ring will make a clinking sound when cover is shaken up and down.
If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.

Flywheel Runout
Check contact surface of flywheel for slight burns or discoloration. Repair flywheel with emery paper.
●
Check the flywheel runout. Refer to EM-103, "FLYWHEEL
DEFLECTION (M/T MODELS)" .
CAUTION:
Measure flywheel outer face (not on knock pin and clutch cover
mounting hole).
●

PBIC2646E

INSTALLATION
1.
2.

3.

Clean clutch disc and input shaft splines to remove grease and dust caused by abrasion.
Apply recommended grease to clutch disc 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 shudder. If it adheres to CSC seal, it
will cause clutch fluid leakage. Wipe off excess grease.
Install clutch disc using tool.
Tool number

4.

: KV30101000 (

—

)

Install clutch cover. Pre-tighten clutch cover bolts.

Revision: June 2006

CL-14

2007 Versa

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
5.
6.

Tighten clutch cover bolts evenly in two steps in the order
shown. Refer to CL-13, "COMPONENTS" .
Install transaxle assembly. Refer to MT-15, "Removal and Installation" .

A

B

CL
PCIB1772E

D

E

F

G

H

I

J

K

L

M

Revision: June 2006

CL-15

2007 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System
Type of clutch control

PFP:00030
ECS00FT3

Hydraulic

Clutch Pedal

ECS00FT4

Clearance ″A″ between clutch pedal and ASCD switch threaded
end while clutch pedal is fully released.

0.74 - 1.96 mm (0.0291 - 0.0772 in)

Clearance ″C″ between clutch pedal and clutch interlock switch
threaded end while clutch pedal is fully depressed.

0.74 - 1.96 mm (0.0291 - 0.0772 in)

Clutch Disc

ECS00FT5

Model

225

Facing size (outer dia. × inner dia. × thickness)
Thickness of disc assembly with load

225 mm × 160 mm × 3.2 mm (8.86 in × 6.30 in × 0.126 in)
7.2 - 7.6 mm (0.283 - 0.299 in) with 5,394 N (550 kg, 1,213 lb)

Runout limit/diameter of the area to be measured

1.0 mm (0.039 in) / 215 mm (8.46 in) dia.

Maximum spline backlash (at outer edge of disc)

1.0 mm (0.039 in)

Wear limit of facing surface to rivet head

0.3 mm (0.012 in)

Clutch Cover

ECS00FT6

Set-load

5,394 N (550 kg, 1,213 lb)

Diaphragm spring lever height

20 - 22 mm (0.79 - 0.87 in)

Uneven limit diaphragm spring toe height

Revision: June 2006

0.7 mm (0.028 in) or less

CL-16

2007 Versa



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