2004 NISSAN TERRANO Service Repair Manual

Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the follow-ing 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 of clutch damper.
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 operating cylinder according to the above procedure.
3. Repeat the above bleeding procedures 1 and 2 several times.
NCL025
INSPECTION AND ADJUSTMENT
CL-6
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NCL028
CLUTCH MASTER CYLINDER
CL-7
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Clutch Master Cylinder
INSPECTION
ICheck cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check return spring for wear or damage. Replace if necessary.
I Check reservoir for deformation or damage. Replace if neces-
sary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
Clutch Operating Cylinder
INSPECTION
ICheck rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check piston spring for wear or damage. Replace if necessary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
SCL420-A
HYDRAULIC CLUTCH CONTROL
CL-8
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REMOVAL AND INSTALLATION
IInstall retainer spring and holder spring.
I Remove release bearing.
I Install release bearing with suitable drift.
NCL017
SCL217
CL145
SCL222
CLUTCH RELEASE MECHANISM
CL-9
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INSPECTION
ICheck release bearing to see that it rolls freely and is free from
noise, cracks, pitting or wear. Replace if necessary.
I Check release sleeve and withdrawal lever rubbing surface for
wear, rust or damage. Replace if necessary.
LUBRICATION
IApply recommended grease to contact surface and rubbing
surface.
Too much lubricant might cause clutch disc facing damage.
DUST COVER SEALING
I Apply recommended sealant to contact surface of dust cover to
transmission case and withdrawal lever and then install dust
cover clip.
NCL026
ECL006
CLUTCH RELEASE MECHANISM
CL-10
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Clutch Disc
INSPECTION
ICheck clutch disc for wear of facing.
Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)
I Check clutch disc for spline backlash and facing runout.
Maximum spline backlash (at outer edge of disc): 1.0 mm (0.039 in)
Runout limit: 1.0 mm (0.039 in)
Distance of runout check point (from hub center): 120 mm (4.72 in)
I Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
INSTALLATION
IApply ªmolykote BR2 plusº grease to contact surface of splines
to clutch disc hub.
Too much lubricant might damage clutch disc facing.
YCL023
YCL024
YCL025
CLUTCH DISC AND CLUTCH COVER
CL-11
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Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
ISet Tools and check height and unevenness of diaphragm
spring.
Diaphragm spring height ªAº: 36.5 - 38.5 mm (1.437 - 1.516 in)
I Check thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammer-
ing on rivets for a slight cracking noise. Replace clutch cover
assembly if necessary.
I Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
I Check pressure plate and clutch disc contact surface for defor-
mation or damage. Replace if necessary.
I Adjust unevenness of diaphragm spring with Tool.
Uneven limit: 0.7 mm (0.028 in)
FLYWHEEL INSPECTION
ICheck contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
I Check flywheel runout.
Runout (Total indicator reading): Refer to EM section. (Inspection Ð CYLINDER
BLOCK)
SCL503
SCL504
SCL468
CLUTCH DISC AND CLUTCH COVER
CL-12
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INSTALLATION
IInsert Tool into clutch disc hub when installing clutch cover and
disc.
I Tighten bolts in numerical order.
I Be careful not to allow grease to contaminate clutch fac-
ing.
YCL026
CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont'd)
CL-13
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