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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