2001 NISSAN ALMERA N16 Clutch

CLUTCH PEDAL ADJUSTMENTNJCL0006S04Pedal StrokeNJCL0006S04011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder 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 stroke ªSº.
Refer to ªSDSº, CL-24.
Pedal Free PlayNJCL0006S04021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
Pedal free play ªAº.
Refer to ªSDSº, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENJCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
+Carefully monitor fluid level at master cylinder during
bleeding operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, then air bubbles
will no longer appear at the damper in the brake fluid.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N´m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont'd)
CL-10

ComponentsNJCL0007
SCL840-A
SCL847-A
CLUTCH MASTER CYLINDER
Components
CL-11

RemovalNJCL00081. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
InstallationNJCL00091. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
: 11 - 14 N´m (1.1 - 1.5 kg-m,8-10ft-lb)
3. Tighten clutch tube flare nut using a flare nut torque wrench.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. After installing clevis pin, install snap pin to connect clutch
pedal to push rod.
5. After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to ªAir Bleeding
Procedureº, CL-10.)
SCL725
DisassemblyNJCL00101. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
InspectionNJCL0011Check the following items, and replace if necessary.
+Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
+Piston with piston cup, for wear or damage
+Return spring, for wear or damage
+Dust cover, for cracks, deformation or damage
+Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Removal
CL-12

AssemblyNJCL00121. Apply rubber lubricant to the sliding part of piston assembly,
and insert piston assembly.
2. After installing stopper to push rod, install stopper ring while
keeping piston assembly depressed by hand, so that piston
assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring
for assembly.
3. Install dust cover.
4. Install clevis to push rod, and tighten lock nut A to the speci-
fied torque.
:8-10N´m(0.8 - 1.1 kg-m, 70 - 95 in-lb)
5. Install spring pin using a pin punch.
CLUTCH MASTER CYLINDER
Assembly
CL-13

ComponentsNJCL0019
YCL003
RemovalNJCL00201. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove union bolt and clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolts, and remove cylin-
der from vehicle.
DisassemblyNJCL0021Remove dust cover, and remove piston assembly from cylinder
body.
InspectionNJCL0022Inspect for following, and replace parts if necessary.
+Damage, foreign material, wear, rust, and pinholes on the cyl-
inder inner surface, piston, and sliding part of piston cup
+Weak spring
+Crack and deformation of dust cover
OPERATING CYLINDER
Components
CL-14

AssemblyNJCL00231. Apply recommended rubber grease to piston cup and piston,
and insert piston assembly.
2. Install dust cover.
InstallationNJCL0024Install the components in the reverse order of removal. Adhere to
the operations described below.
CAUTION:
Install the hose without twisting it.
+The copper washer of the union bolt should not be reused.
Always use a new copper washer for installation.
+After finishing the operation, bleed air from the clutch
piping connector and operating cylinder. Refer to ªAir
Bleeding Procedureº, CL-10.
OPERATING CYLINDER
Assembly
CL-15

SCL729
RemovalNJCL00421. Remove fuel filter mounting bracket.
2. Remove air cleaner and air duct.
3. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
4. Remove flare nut using a flare nut wrench.
5. Remove clutch hose and clutch tube.
SCL730
InstallationNJCL00431. When installing clutch hose to bracket, face lock plate in the
correct direction as shown to secure clutch hose.
CAUTION:
Install clutch hose without twisting or bending it.
2. Tighten flare nut to the specified torque, using a flare nut
wrench.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage flare nut and clutch tube.
3. Install clutch hose to operating cylinder, and tighten mounting
bolts to the specified torque.
: 17 - 19 N´m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. After finishing the operation, bleed air from the clutch piping.
Refer to ªBleeding Procedureº, CL-10.
PIPING
Removal
CL-16

ComponentsNJCL0044
SCL819
SCL820
RemovalNJCL00451. Remove manual transaxle from vehicle. Refer to MT-23,
ªRemovalº.
2. Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch lever.
3. Support clutch lever claws with an appropriate wood block,
align retaining pin with A in the figure, and drive out spring pin
using a pin punch.
4. Pull out withdrawal lever and remove clutch lever.
SCL733
InspectionNJCL0046+Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.
+Replace the withdrawal lever if its contact surface is worn
abnormally.
+Replace the clutch lever if its contact surface is worn abnor-
mally.
+Replace the dust seal if it is deformed or cracked.
InstallationNJCL0047CAUTION:
+Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.
+Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.
CLUTCH RELEASE MECHANISMRS5F30A, RS5F70A
Components
CL-17