1999 NISSAN PRIMERA clutch

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS AND PREPARATION.......................... 2
Precautions ................................................................ 2
Preparation ................................................................ 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING................................................... 3
NVH Troubleshooting Chart....................................... 3
CLUTCH SYSTEM......................................................... 4
INSPECTION AND ADJUSTMENT............................... 5
Inspecting and Adjusting Clutch Pedal ...................... 5
Bleeding Procedure ................................................... 7HYDRAULIC CLUTCH CONTROL............................... 8
Clutch Master Cylinder .............................................. 8
Clutch Operating Cylinder ......................................... 9
Clutch Damper ......................................................... 10
CLUTCH RELEASE MECHANISM.............................. 11
CLUTCH DISC AND CLUTCH COVER...................... 13
Clutch Disc............................................................... 13
Clutch Cover and Flywheel ..................................... 14
SERVICE DATA AND SPECIFICATIONS (SDS)........ 15
General Specifications ............................................. 15
Inspection and Adjustment ...................................... 16
CL

Precautions
lRecommended fluid is brake fluid ªDOT 4º.
lDo not reuse drained brake fluid.
lBe careful not to splash brake fluid on painted areas.
lWhen removing and installing clutch piping, use Tool.
lUse new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
lNever use mineral oils such as gasoline or kerosene. It
will ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do
not use compressed air.
Preparation
SPECIAL SERVICE TOOLS
COMMERCIAL SERVICE TOOLS
SBR820B GG94310000
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
NT406
Removing and installing clutch piping
a: 10 mm (0.39 in)
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
NT645
Installing clutch cover and clutch disc
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20050240
Diaphragm spring
adjusting wrench
NT404
Adjusting unevenness of diaphragm spring
of clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
Tool name Description
Equivalent to
GG94310000
p1Flare nut crows foot
p2Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
PRECAUTIONS AND PREPARATION
CL-2

NVH Troubleshooting Chart
Use the chart below to help you to find the cause of the symptom. The numbers indicate the order of
inspection.
Check each part in order. If necessary, repair or replace these parts.
Reference pageCL-5
CL-7
CL-8
CL-9
Refer to EM section
CL-11
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-13
CL-14
CL-14
CL-14
CL-14
SUSPECTED PARTS
(Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING ( Out of tip alignment)
CLUTCH COVER (Distortion)
FLYWHEEL (Discoloration)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 4 5 5 5 5 5 5 6 6 7
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
CL-3

YCL007
CLUTCH SYSTEM
CL-4

Inspecting and Adjusting Clutch Pedal
Inspect and adjust clutch pedal stroke.
Pedal stroke ªSº:
Refer to SDS, CL-16.
NCL057
Pedal bracket
Pedal stopper
bolt
Pedal pad
NCL058 Master cylinder
push rod
Pedal bracket
Pedal stopper
bolt
B Pedal fully
depressed position
A Pedal fully up
position
INSPECTION AND ADJUSTMENT
CL-5

INSPECITON
Pedal stroke
Check clutch pedal stroke using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the
middle of the clutch pedal pad. Place a book/clipboard on the driver's set to set a reference point, ensure
the book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard.
Measure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified
pedal stroke in the table, adjust actual pedal stroke if necessary (refer toªADJUSTMENTº).
Note:
lDo not use steering wheel as a reference point, angle gives incorrect reading.
lEnsure there is no interference between the floor carpet and clutch pedal when fully depressed.
Pedal free play
Check pedal free play. If out of specification, refer toªADJUSTMENTº.
lPush on the clutch pedal until resistance is felt, and check the distance the pedal moves.
ADJUSTMENT
Pedal stroke
1. Loosen the pedal stopper bolt completely (so there is no contact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cylinder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free play.
Pedal free play
1. Adjust pedal free play to the specified value with the master cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
lPush on the clutch pedal until resistance is felt, and check the distance the pedal moves.
Pedal free play ªAº:
Refer to SDS, CL-16.
SCL702
INSPECTION AND ADJUSTMENT
Inspecting and Adjusting Clutch Pedal
(Cont'd)
CL-6

Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
Carefully monitor fluid level at master cylinder during bleed-
ing operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve of clutch
operating cylinder.
c. Fully depress clutch pedal several times.
d. With clutch pedal depressed, open bleeder valve to release
air.
e. Close bleeder valve.
f. Repeat steps (c) through (e) above until brake fluid flows
from air bleeder valve without air bubbles.
2. Bleed air from clutch damper according to the above proce-
dure.
3. Repeat the above bleeding procedures 1 and 2 several
times.
.NCL005
.Operating cylinder
.Air bleeder valve
NCL006 Air bleed valve
.Clutch
damper
INSPECTION AND ADJUSTMENT
CL-7

Clutch Master Cylinder
DISASSEMBLY AND ASSEMBLY
lPush piston into cylinder body with screwdriver when remov-
ing and installing valve stopper.
lCheck direction of piston cups.
INSPECTION
lCheck cylinder and piston contact surfaces for uneven wear,
rust or damage. Replace if necessary.
lCheck piston and piston cup for wear or damage. Replace if
necessary.
lCheck return spring for wear or damage. Replace if neces-
sary.
lCheck reservoir for deformation or damage. Replace if
necessary.
lCheck dust cover for cracks, deformation or damage.
Replace if necessary.
YCL008
HYDRAULIC CLUTCH CONTROL
CL-8