Page 865 of 2896

CL-8
CLUTCH FLUID
Revision: June 20062007 Versa
CLUTCH FLUIDPFP:00017
Air Bleeding ProcedureECS00FSY
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.
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 con-
nector (2) when fluid pressure is applied in the tube.
6. Slide clutch tube (1) in the direction of the arrow as shown, then
bleed the air from the tube.
7. Return clutch tube (1) and lock pin (2) to their original positions.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 2 to 8 until no bubbles are observed in the clutch
fluid.
PCIB1494E
PCIB1495E
Dimension A : 5 mm (0.20 in)
PCIB1496E
Page 866 of 2896

CLUTCH MASTER CYLINDER
CL-9
D
E
F
G
H
I
J
K
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MA
B
CL
Revision: June 20062007 Versa
CLUTCH MASTER CYLINDERPFP:30610
Removal and InstallationECS00FSZ
REMOVAL
1. Use one of the following methods to remove hose from master cylinder.
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.
CAUTION:
Keep painted surface of the body and other parts free of clutch fluid. If it spills, wipe up immedi-
ately and wash the affected area with water.
2. Remove master cylinder rod end from clutch pedal assembly.
3. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
4. Rotate master cylinder clockwise by 45° and remove from the vehicle.
INSTALLATION
1. 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.
2. Install master cylinder rod end to clutch pedal.
PCIB1491E
PCIB1497E
SCIA1286E
Page 867 of 2896
CL-10
CLUTCH MASTER CYLINDER
Revision: June 20062007 Versa
3. Install clutch tube (1) fully into connector of master cylinder (2).
4. Install lock pin (3) fully into connector of master cylinder (2).
5. Fill with new clutch fluid and bleed air from the system. Refer to
CL-8, "
CLUTCH FLUID" .
6. After completing this procedure, inspect and adjust the clutch
pedal. Refer to CL-5, "
On-vehicle Inspection and Adjustment" .
PCIB1500E
Page 868 of 2896

CSC (CONCENTRIC SLAVE CYLINDER)
CL-11
D
E
F
G
H
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MA
B
CL
Revision: June 20062007 Versa
CSC (CONCENTRIC SLAVE CYLINDER)PFP:30500
Removal and InstallationECS00FT0
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
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-
ately and wash the affected area with water.
REMOVAL
1. Remove transaxle assembly. Refer to MT-15, "Removal and Installation" .
2. Remove CSC bolts and the CSC from clutch housing.
INSTALLATION
1. 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.
2. Install transaxle assembly. Refer to MT-15, "
Removal and Installation" .
3. Bleed the air from the clutch hydraulic system. Refer to CL-8, "
Air Bleeding Procedure" .
PCIB1498E
Page 869 of 2896
CL-12
CLUTCH PIPING
Revision: June 20062007 Versa
CLUTCH PIPINGPFP:30650
Removal and InstallationECS00FT1
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. Remove lock pin (2) from clutch damper (3).
2. Remove clutch tube (1) from clutch damper (3).
3. Remove clutch damper (3) from bracket (4).
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" .
1. Clutch tube 2. Lock pin 3. CSC
4. Clutch damper 5. Master cylinder 6. Clutch pedal
PCIB1499E
WCIA0597E
Page 870 of 2896

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-13
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
CLUTCH DISC, CLUTCH COVER AND FLYWHEELPFP:30100
Removal and InstallationECS00FT2
COMPONENTS
CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylin-
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.
Be careful not to apply any grease to the clutch disc facing, pressure plate surface and flywheel
surface.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to MT-15, "Removal and Installation" .
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
Check clutch disc for backlash of spline and runout of facing.
Check clutch disc for burns, discoloration or oil or grease leak-
age. 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.
1. Flywheel 2. Clutch disc *1, *2 3. Clutch cover
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.
WCIA0637E
Maximum backlash of spline
(at outer edge of disc): 1.0 mm (0.039 in)
Distance of runout check point
(from hub center): 215 mm (8.46 in)
Maximum allowable spline backlash : 1.0 mm (0.039 in)
SCL221
Page 871 of 2896

CL-14
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Revision: June 20062007 Versa
Use a suitable tool to measure the depth to clutch disc facing
rivet heads. If it exceeds the allowable wear limit, replace clutch
disc.
Clutch Cover
Check clutch cover installed on vehicle for unevenness of diaphragm
spring toe height.
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
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 discolora-
tion. 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).
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and dust caused by abrasion.
2. 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.
3. Install clutch disc using tool.
4. Install clutch cover. Pre-tighten clutch cover bolts.Wear limit of facing
surface to rivet head: 0.3 mm (0.012 in)
SCL229
Uneven limit : 0.7 mm (0.028 in) or less
Tool number A : ST20050240 ( — )
PCIB1502E
PBIC2646E
Tool number : KV30101000 ( — )
Page 872 of 2896
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-15
D
E
F
G
H
I
J
K
L
MA
B
CL
Revision: June 20062007 Versa
5. Tighten clutch cover bolts evenly in two steps in the order
shown. Refer to CL-13, "
COMPONENTS" .
6. Install transaxle assembly. Refer to MT-15, "
Removal and Instal-
lation" .
PCIB1772E