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CL-4
< SERVICE INFORMATION >
PREPARATION
PREPARATION
Special Service ToolINFOID:0000000005928991
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolINFOID:0000000005928992
Tool number
(Kent-Moore No.)
Tool name Description
ST20050240
(—)
Diaphragm spring adjusting wrench Adjusting unevenness of diaphragm spring of
clutch cover
ZZA0508D
Tool name
Description
Clutch aligning bar Installing clutch cover and clutch disc
1: Assembly
2: Sleeve
3: Adapter
Power tool Loosening bolts and nuts
PCIB0017E
PBIC0190E
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGCL-5
< SERVICE INFORMATION >
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NOISE, VIBRATION AND HARSHN ESS (NVH) TROUBLESHOOTING
NVH Troubleshooting ChartINFOID:0000000005928993
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageCL-6CL-9EM-197CL-13CL-16EM-219
SUSPECTED PARTS (Possible cause)
CLUTCH PEDAL (Inspection and adjustment)
CLUTCH LINE (Air in line)
ENGINE MOUNTING (Loose)
CSC (Concentric slave cylinder) (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runou t 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)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
Symptom Clutch grabs/chatters
122 2 2 2
Clutch pedal spongy 1
Clutch noisy 1
Clutch slips 1 2 23 4 5
Clutch does not disengage 12 55555 5667
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CL-6
< SERVICE INFORMATION >
CLUTCH PEDAL
CLUTCH PEDAL
On-vehicle Inspection and AdjustmentINFOID:0000000005928994
1. Check to see if the master cylinder rod end moves freely. Itshould not be bound by the clutch pedal.
a. If the rod end does not move freely, check that the ASCD switch, if equipped, is not applying pressure to the clutch pedal causing
the rod end to bind. To adjust, disconnect the ASCD switch elec-
trical connector and turn the ASCD switch.
b. Connect the ASCD switch electrical connector, if equipped.
c. Verify that the master cylinder rod end moves freely. It should not be bound by the clutch pedal.
d. If the rod end does not move freely, remove the rod end and check for deformation or damage on the rod end. Leave the rod
end removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the pedal up and down to determine if it moves
freely.
b. If any sticking is noted, replace the clutch pedal assembly. Re-verify that the master cylinder rod end
moves freely.
3. Adjust clutch interlock switch (2) position so that clearance between clutch pedal (1) and thread end of clutch interlock
switch (2), with clutch pedal fully depressed, is within specifica-
tion (C).
Clearance C : 0.74 - 1.96 mm (0.0291 - 0.0772 in)
PCIB1491E
WCIA0594E
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CLUTCH PEDALCL-7
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4. Adjust ASCD clutch switch (1 ), if equipped. Position so that
clearance between clutch pedal (2) and thread end of ASCD
clutch switch (1), with clutch pedal fully released, is within speci-
fication (A).
5. Check the clutch hydraulic system components (clutc h master cylinder, clutch operating cylinder, clutch
withdrawal lever and clutch release bearing) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-9, "
Air
Bleeding Procedure".
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Us e of a vacuum assist or
power bleeder will not purge all of the air from the system.
Removal and InstallationINFOID:0000000005928995
COMPONENTS
Clearance A : 0.74 - 1.96 mm (0.0291 - 0.0772 in)
WCIA0595E
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CL-8
< SERVICE INFORMATION >
CLUTCH PEDAL
REMOVAL
1. Remove instrument lower finisher. Refer to IP-12, "Removal and Installation".
2. Disconnect clutch interlock switch and ASCD clutch switch harness connectors, if equipped.
3. Remove clutch switch harness clamp from clutch pedal assembly.
4. Disconnect master cylinder rod end from clutch pedal lever.
5. Remove clutch pedal assembly nuts, and then remove clutch pedal assembly.
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-6, "
On-vehicle Inspection and
Adjustment".
1. Clutch pedal assembly 2. Lock nut 3. Clutch interlock switch
4. ASCD clutch switch 5. Lock nut
WCIA0596E
PCIB1491E
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CLUTCH FLUIDCL-9
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CLUTCH FLUID
Air Bleeding ProcedureINFOID:0000000005928996
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
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.
• Carefully monitor fluid level in reservoir tank during bleeding operation.
1. Fill master cylinder reservoir tank with new clutch fluid.
2. Connect a transparent vinyl tube and container to the bleeding connector (1) on the CSC.
3. Depress and release the clutch pedal slowly and fully 15 times at an interval of two to three seconds and release the clutch
pedal.
4. Push in the lock pin (1) of the bleeding connector (2), and maintain the position. • RS5F91R transaxle models
CAUTION:
Hold the lock pin in to preven t the bleeding connector from
separating when fluid pressure is applied.
• RS6F94R transaxle models
CAUTION:
Hold the lock pin in to preven t the bleeding connector from
separating when fluid pressure is applied.
PCIB1494E
PCIB1495E
JPDIB0041ZZ
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CL-10
< SERVICE INFORMATION >
CLUTCH FLUID
5. Slide the clutch tube (1) in the direction of the arrow as shown tothe dimension (A). (For RS5F91R transaxle models)
2: bleeding connector
6. Slide bleeding connector (1) in the direction of the arrow as shown to the dimension (A). (For RS6F94R transaxle models)
2: clutch housing
7. Depress the clutch pedal soon and hold it, and then bleed air from the piping. wait for 5 seconds.
CAUTION:
Hold the clutch pedal down to prevent air from getting back
into the clutch system.
8. Return the clutch tube and lock pin to their original positions.
9. Release clutch pedal and wait for 5 seconds.
10. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid. Dimension (A) : 5 mm (0.20 in)
JPDIB0147ZZ
Dimension (A) : 10 mm (0.39 in)
JPDIB0042ZZ
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CLUTCH MASTER CYLINDERCL-11
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CLUTCH MASTER CYLINDER
Removal and InstallationINFOID:0000000005928997
REMOVAL
1. Remove the battery, battery tray and brackets. Refer to SC-5.
2. Remove the air cleaner and air duct. Refer to EM-25, "
Removal and Installation" (HR16DE models), EM-
135, "Removal and Installation" (MR18DE models).
3. 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:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
4. Remove master cylinder rod end from clutch pedal assembly.
5. Remove lock pin (1) from connector of master cylinder (2) and separate clutch tube (3).
6. 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
Revision: May 2010 2011 Versa