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CL-12
< SERVICE INFORMATION >
CLUTCH MASTER CYLINDER
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 toCL-9
.
6. After completing this procedure, inspect clutch pedal operation. Refer to CL-6, "
On-vehicle Inspection and Adjustment".
7. Install the air cleaner and air duct. Refer to EM-25, "
Removal
and Installation" (HR16DE models), EM-135, "Removal and
Installation" (MR18DE models).
8. Install the battery. Refer to SC-5
.PCIB1500E
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CSC (CONCENTRIC SLAVE CYLINDER)CL-13
< SERVICE INFORMATION >
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CSC (CONCENTRIC SLAVE CYLINDER)
Exploded ViewINFOID:0000000005928998
HR16DE engine models
MR18DE engine models
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every time when removing transaxle assembly. At th is timing, dust on the sliding parts may damage
a seal of CSC and may cau se clutch fliud leakage.
• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it sp ills, wipe up immediately
and wash the affected area with water.
Removal and InstallationINFOID:0000000005928999
REMOVAL
1. Remove transaxle assembly. Refer to EM-82, "Removal and Installation" (HR16DE models), EM-197,
"Removal and Installation" (MR18DE models).
JPDIB0146GB
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)
JPDIB0040GB
1. Transaxle assembly2. CSC (Concentric Slave Cylinder)
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CL-14
< SERVICE INFORMATION >
CSC (CONCENTRIC SLAVE CYLINDER)
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 CL-13, "Exploded View".
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 EM-82, "
Removal and Installation" (HR16DE models), EM-197,
"Removal and Installation" (MR18DE models).
3. Bleed the air from the clutch hydraulic system. Refer to CL-9, "
Air Bleeding Procedure".
PCIB1498E
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CLUTCH PIPINGCL-15
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CLUTCH PIPING
Removal and InstallationINFOID:0000000005929000
Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected
area with water.
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 clutch master cylinder. • Drain clutch fluid from reservoir tank and remove hose.
• Remove hose from clutch master cylinder. Immediat ely 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 clutch tube lock pin from clutch master cylinder.
5. Remove clutch tube lock pin at clutch housing.
6. Remove clutch tube lock pins (2) from clutch damper (3).
7. Remove clutch tube (1) from clutch damper (3).
8. Remove clutch damper (3) from bracket (4).
INSTALLATION
Installation is in the reverse order of removal.
• Make sure that all tubes are fu lly 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-9, "
Air Bleeding Procedure".
1. Clutch tube2. Clutch tube lock pin 3. CSC
4. Clutch damper 5. Clutch master cylinder 6. Clutch pedal
PCIB1499E
WCIA0597E
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CL-16
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and InstallationINFOID:0000000005929001
COMPONENTS
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to CL-13, "
Removal and Installation".
• Never bring any grease to the clutch disc faci ng, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean clutch disc using solvent.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to MT-17, "Removal and Installation" (RS5F91R
models), MT-61, "
Removal and Installation" (RS6F94R models).
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
• Measure clutch disc runout and spline backlash. If either measure- ment exceeds the specificat ion, replace clutch disc.
• Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
1. Flywheel 2. Clutch disc 3. Clutch cover
4. Input shaft A. First step (MR18DE engine models) B. First step (HR16DE engine models)
C. Final step Apply lithium-based grease including molybdenum disulphide
JPDIB0038GB
Runout and backlash : Refer to CL-19, "Clutch Disc".
SCL221
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CLUTCH DISC, CLUTCH COVER AND FLYWHEELCL-17
< SERVICE INFORMATION >
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• Determine the wear limit of clutch facing (depth to the rivet head). If measurement exceeds specific ations, replace clutch disc.
Clutch Cover
• With the check clutch cover installed on vehicle Check the dia-
phragm spring toe height. If unevenness exceeds specifications,
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 using 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 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 discoloration.Repair flywheel with emery paper.
• Check the flywheel runout. Refer to EM-97, "
Inspection" (HR16DE
models), EM-219, "
Inspection After Disassembly" (MR18DE mod-
els).
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 sl ip or shudder. If it adheres to CSC seal, it
will cause clutch fluid l eakage. Wipe off excess grease.
Clutch facing wear : Refer to
CL-19, "
Clutch Disc".
SCL229
Uneven limit of diaphragm
spring toe height: Refer to CL-19, "Clutch
Cover".
Tool number A : ST20050240 ( — )
PCIB1502E
PBIC2646E
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CL-18
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
3. Install clutch disc using suitable clutch aligner (A).• B: HR16DE
• C: MR18DE
4. Install clutch cover. Pre-tighten clutch cover bolts.
5. Tighten clutch cover bolts evenly in two steps in the order shown.
6. Install transaxle assembly. Refer to MT-17, "
Removal and Instal-
lation" (RS5F91R) or MT-61, "Removal and Installation"
(RS6F94R).
JPDIB0044ZZ
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SERVICE DATA AND SPECIFICATIONS (SDS)CL-19
< SERVICE INFORMATION >
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SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control SystemINFOID:0000000005929002
Clutch PedalINFOID:0000000005929003
Clutch DiscINFOID:0000000005929004
Clutch CoverINFOID:0000000005929005
Type of clutch control Hydraulic
Clearance between clutch pedal and ASCD switch threaded end
while clutch pedal is fully released (if equipped). 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Clearance between clutch pedal and clutch interlock switch
threaded end while clutch pedal is fully depressed. 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Engine type
HR16DEMR18DE
Model 200225
Facing size (outer dia. × inner dia. × thickness) 200 mm x 140 mm x 3.1 mm (7.87 in x
5.51 in x 0.122 in) 225 mm ×
160 mm × 3.2 mm (8.86 in ×
6.30 in × 0.126 in)
Thickness of disc assembly with load 7.1 - 7.5 mm (0.280 - 0.295 in) with 4,658
N (475 kg, 1,047 lb) 7.2 - 7.6 mm (0.283 - 0.299 in) with
5,394 N (550 kg, 1,213 lb)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 190 mm (7.48 in) dia 1.0 mm (0.039 in) / 215 mm (8.46 in)
dia.
Maximum spline backlash (at outer edge of disc) 0.8 mm (0.031 in)0.9 mm (0.035 in)
Wear limit of facing (depth to the rivet head) 0.3 mm (0.012 in)0.3 mm (0.012 in)
Engine type HR16DEMR18DE
Set-load 4,658 N (475.1 kg, 1,047.1 lb) 5,394 N (550 kg, 1,213 lb)
Diaphragm spring lever height 29 - 31 mm (1.14 - 1.22 in)20 - 22 mm (0.79 - 0.87 in)
Uneven limit of diaphragm spring toe height 0.7 mm (0.028 in) or less0.7 mm (0.028 in) or less
Revision: May 2010 2011 Versa