Text preview for : Trasmissione 1.pdf part of NISSAN Almera Tino Info. General - Accelerator Control, Fuel, Exaust System - Axle Front e Rear - Starting Charging - Clutch - Fuse Box - Maintenance - Suspension - Steering System - Trasmission - pag. 260
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CLUTCH
C TRANSMISSION/TRANSAXLE
SECTION
CL
A
B
CLUTCH
CL
D
CONTENTS
RS6F51R
PRECAUTIONS ......................................................... 2 . Caution .................................................................... 2 . PREPARATION .......................................................... 3 . Special Service Tools .............................................. 3 . Commercial Service Tool ........................................ 3 . NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................... 4 . NVH Troubleshooting Chart .................................... 4 . CLUTCH PEDAL ....................................................... 5 . On-Vehicle Inspection and Adjustment ................... 5 . CLUTCH PEDAL STROKE INSPECTION ........... 5 . CLUTCH PEDAL FREE PLAY INSPECTION ...... 5 . CLUTCH PEDAL STROKE ADJUSTMENT ......... 5 . CLUTCH PEDAL FREE PLAY ADJUSTMENT ..... 6 Removal and Installation ......................................... 6 . INSPECTION AFTER REMOVAL ........................ 7 . CLUTCH FLUID ......................................................... 8 . Air Bleeding Procedure ........................................... 8 . CLUTCH MASTER CYLINDER ................................. 9 . Removal and Installation ......................................... 9 . REMOVAL ............................................................ 9 . INSTALLATION .................................................... 9 . Disassembly and Assembly .................................. 10 . DISASSEMBLY .................................................. 10 . INSPECTION AFTER DISASSEMBLY .............. 10 . ASSEMBLY ........................................................ 10 . OPERATING CYLINDER ......................................... 11 . Removal and Installation ....................................... 11 . REMOVAL .......................................................... 11 . INSTALLATION .................................................. 11 . Disassembly and Assembly ................................... 11 . DISASSEMBLY .................................................. 11 . INSPECTION AFTER DISASSEMBLY ............... 11 . ASSEMBLY ........................................................ 12 . CLUTCH PIPING ...................................................... 13 . Removal and Installation ....................................... 13 . CLUTCH RELEASE MECHANISM .......................... 14 . Removal and Installation ....................................... 14 . REMOVAL .......................................................... 14 . INSPECTION AFTER REMOVAL ...................... 14 . INSTALLATION .................................................. 14 . CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 16 ... Removal and Installation ....................................... 16 . REMOVAL .......................................................... 16 . INSPECTION AND ADJUSTMENT AFTER REMOVAL .......................................................... 16 . INSTALLATION .................................................. 17 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 18 . Clutch Control System ........................................... 18 . Clutch Master Cylinder .......................................... 18 . Clutch Operating Cylinder ..................................... 18 . Clutch Disc ............................................................ 18 . Clutch Cover .......................................................... 18 . Clutch Pedal .......................................................... 18 .
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CL-1
PRECAUTIONS
[RS6F51R]
PRECAUTIONS Caution
[RS6F51R]
PFP:00001
ECS0094X
Recommended fluid is brake fluid "DOT 3" or "DOT 4". q Never reuse drained brake fluid. q Be careful not to splash brake fluid on painted areas. q When removing and installing clutch piping, use Tool. q Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder. q Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system. WARNING: After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
q
SBR686C
CL-2
PREPARATION
[RS6F51R]
PREPARATION Special Service Tools
Tool name Tool number Description
PFP:00002
A
ECS0094Y
B
Pin punch ST23550000 Tip diameter: 4.5 mm (0.177 in) dia.
ZZA0515D
CL
Removing and installing master cylinder spring pin
D
E
Diaphragm adjusting wrench ST20050240 Adjusting unevenness of diaphragm spring of clutch cover
F
ZZA0508D
G
Clutch aligning bar ST20630000 a: 15.8 mm (0.622 in) dia. b: 22.9 mm (0.902 in) dia. c: 45.0 mm (1.077 in)
S-NT405
Installing clutch cover and disc
H
I
ECS0094Z
Commercial Service Tool
Tool name Description
J
1. Flare nut crowfoot 2. Torque wrench a: 10 mm (0.39 in)
S-NT360
K
Removing and installing clutch piping
L
M
CL-3
Symptom Clutch slips CLUTCH PEDAL (Free play out of adjustment) CLUTCH LINE (Air in line) MASTER CYLINDER PISTON CUP (Damaged) OPERATING CYLINDER PISTON CUP (Damaged) ENGINE MOUNTING (Loose) RELEASE BEARING (Worn, dirty or damaged) CLUTCH DISC (Out of true) CLUTCH DISC (Runout is excessive) CLUTCH DISC (Lining broken) CLUTCH DISC (Dirty or burned) CLUTCH DISC (Oily) 2 2 CLUTCH DISC (Worn out) 2 2 CLUTCH DISC (Hardened) 2 CLUTCH DISC (Lack of spline grease) 5 DIAPHRAGM SPRING (Damaged) 6 3 DIAPHRAGM SPRING (Out of tip alignment) 6 2 PRESSURE PLATE (Distortion) 7 4 FLYWHEEL (Distortion) 5 2 1 1 CL-5 CL-8 CL-9 CL-11 EM-197 CL-14 CL-16 CL-16 CL-16 CL-16 CL-16 CL-16 CL-16 CL-16 CL-17 CL-17 CL-17 CL-17 1 2 2 Clutch noisy Clutch pedal spongy Clutch grabs/chatters
Reference page
SUSPECTED PARTS (Possible cause)
Clutch does not disengage 1 2 3 4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.
CL-4
1 5 5 5 5 5
[RS6F51R]
PFP:00003
ECS00950
CLUTCH PEDAL
[RS6F51R]
CLUTCH PEDAL On-Vehicle Inspection and Adjustment
CLUTCH PEDAL STROKE INSPECTION
PFP:46540
A
ECS00951
Check clutch pedal stroke by using a 1-meter rule to measure the total pedal stroke. Place end of rule onto the B middle of the clutch pedal pad. Place a book/clipboard on the driver's seat to set a reference point, ensure the book/clipboard does not move during pedal depression. Mark (A) the pedal fully up position on the rule. Depress the clutch pedal and mark (B) the rule again next to the reference point on the book/clipboard. Measure the distance between the marks (A and B), this is the actual pedal stroke (S). Check the specified pedal CL stroke in the table, adjust actual pedal stroke if necessary (refer to CL-5, "CLUTCH PEDAL STROKE ADJUSTMENT" ). NOTE: D q Do not use steering wheel as a reference point, angle gives incorrect reading. q Ensure there is no interference between the floor carped and clutch pedal when fully depressed. E
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NCL058
M
CLUTCH PEDAL FREE PLAY INSPECTION
Check pedal free play, if out of specification refer to CL-5, "CLUTCH PEDAL STROKE ADJUSTMENT" . q Push on the clutch pedal until resistance is felt, and check the distance the pedal moves.
SCL702
CLUTCH PEDAL STROKE ADJUSTMENT
1. 2. Loosen the pedal stopper bolt completely (so there is on contact between pedal and stopper bolt). Adjust pedal stroke to the specified value with the master cylinder push rod.
CL-5
CLUTCH PEDAL
[RS6F51R]
3. 4. Adjust the pedal stopper bolt until it is just in contact with the pedal, then tighten the lock nut. Once stroke is set to specification, adjust clutch pedal free play. Clutch pedal stroke "S": 1. 2.
q
155 - 160 mm (6.10 - 6.30 in)
CLUTCH PEDAL FREE PLAY ADJUSTMENT
Adjust pedal free play to the specified value with the master cylinder push rod. 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 "A": 1 - 3 mm (0.04 - 0.12 in)
ECS00952
Removal and Installation
MCIA0125E
MCIA0126E
1. 4.
Clutch pedal assembly Snap pin
2. 5.
Clevis pin Stopper bolt
3. 6.
Bushing Clutch pedal
NOTE: Install clutch pedal assembly and adjust the pedal height. Tighten stopper bolt to the specified torque.
CL-6
CLUTCH PEDAL
[RS6F51R]
INSPECTION AFTER REMOVAL
q
q
Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace the clutch pedal. Check assist spring for settling. If settling is found, replace the assist spring.
A
B
CL
D
E
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CL-7
CLUTCH FLUID
[RS6F51R]
CLUTCH FLUID Air Bleeding Procedure
PFP:00017
ECS00953
CAUTION: q Monitor fluid level in the reservoir to make sure it does not empty. q Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area with water. q Bleed the operating cylinder. 1. Fill the master cylinder reservoir tank with new clutch fluid. 2. Connect a transparent vinyl hose to the air bleeder. 3. Depress the clutch pedal slowly and fully a few times at an interval of 2 to 3 seconds and hold it. 4. With clutch pedal depressed, open air bleeder. 5. Close air bleeder. 6. Release clutch pedal and wait for 5 seconds. 7. Repeat steps 3 to 6 until no bubbles can be observed in the brake fluid.
MCIA0127E
Air bleeder : 5.9 - 9.8 N·m (0.6 - 1.0 kg·m, 52 - 86 in·lb)
CL-8
CLUTCH MASTER CYLINDER
[RS6F51R]
CLUTCH MASTER CYLINDER Removal and Installation
PFP:30610
A
ECS00954
B
CL
D
E
F
SCIA0324E
G
1. 4. 7.
Clevis pin Lock nut Stopper
2. 5. 8.
Snap pin Dust cover Push rod
3. 6. 9.
Clevis Stopper ring Piston assembly
H
10. Return spring 13. Spring pin 16. Hose
11. Cylinder body 14. Nipple
12. Seal 15. Clamp
I
REMOVAL
1. Using one of the following methods, remove hose from the nipple. q Drain clutch fluid from reservoir tank and remove hose. q Remove hose from the nipple. 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. Using a flare nut wrench, remove clutch tube. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal. First remove the mounting nuts on the master cylinder assembly, and then the master cylinder assembly from the vehicle. Connect clutch tube to master cylinder assembly and temporarily tighten flare nut. Install master cylinder assembly and tighten mounting nut to the specified torque. Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque. Attach clevis of the clevis pin to the clutch pedal. Attach snap pin to the clevis pin. Install hose to the nipple. After completing this procedure, inspect and adjust pedal height and then bleed the clutch tube. Refer to CL-5, "On-Vehicle Inspection and Adjustment" , CL-8, "Air Bleeding Procedure"
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K
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2. 3. 4.
M
INSTALLATION
1. 2. 3. 4. 5. 6. 7.
CL-9
CLUTCH MASTER CYLINDER
[RS6F51R]
Disassembly and Assembly
DISASSEMBLY
1. 2. 3. 4. Using a pin punch, remove spring pin, nipple and seal from the cylinder body. Loosen push rod lock nut. Remove clevis and lock nut. Remove dust cover. Remove stopper ring and stopper. Remove push rod from cylinder body while holding it securely to reduce possibility of the piston popping out. Remove piston assembly and return spring.
ECS00955
5.
CLB0166D
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned. q Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole q Damaged or deformed nipple or reservoir tank q Settling of the spring q Cracked or deformed dust cover
ASSEMBLY
1. 2. 3. 4. 5. Apply rubber lubricant to internal surface of the cylinder body, sliding surface of piston assembly, and the piston cup. Insert piston assembly and return spring. Apply silicon grease to push rod and install stopper. Install stopper ring while holding down the push rod by hand to prevent the piston assembly from popping out. Install dust cover. Install clevis to the push rod and tighten lock nut to the specified torque. Install seal and nipple to the cylinder body. Using a pin punch, install spring pin.
CL-10
OPERATING CYLINDER
[RS6F51R]
OPERATING CYLINDER Removal and Installation
PFP:30620
A
ECS00956
B
CL
D
E
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MCIA0128E
1. 4. 7.
Cylinder body Piston Air bleeder
2. 5. 8.
Piston spring Push rod Union bolt
3. 6. 9.
Piston cup Dust cover Copper washer
J
10. Clutch hose
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REMOVAL
1. Drain clutch fluid. CAUTION: Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area with water. Remove clutch hose from the operating cylinder. Remove operating cylinder mounting bolt and remove operating cylinder.
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2. 3.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal. q Install hose with care so that it will not be bent or twisted. q After completing the procedure, bleed the clutch tube. Refer to CL-8, "Air Bleeding Procedure" .
Disassembly and Assembly
DISASSEMBLY
q
ECS00957
Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside the cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned. q Damage to cylinder inner surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole q Settling of the spring
CL-11
OPERATING CYLINDER
[RS6F51R]
q
Cracked or deformed dust cover Apply rubber lubricant to cylinder body inner surface and rubber grease to the piston cup and piston. Insert piston assembly into the cylinder body. Apply rubber grease to dust cover and install push rod and dust cover.
ASSEMBLY
1. 2.
CL-12
CLUTCH PIPING
[RS6F51R]
CLUTCH PIPING Removal and Installation
PFP:30650
A
ECS00958
Carefully observe the following steps during clutch tube removal and installation. q Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area B with water. q To fix clutch hose on the bracket, position hose clasp on the bracket locating embossment and drive the lock plate vertically CL from above. Be careful not to bend or twist the hose. Do not scratch or damage the clutch hose. q Tighten clutch tube flare nut to the specified torque below: D : 14.8 - 17.6 N·m (1.5 - 1.8 kg·m, 11 - 13 ft·lb)
q
Tighten clutch hose union bolt to the specified torque: : 16.7 - 19.6 N·m (1.7 - 2.0 kg·m, 13 - 14 ft·lb)
MCIA0129E
E
q
CAUTION: Do not reuse the copper washer. After installation, bleed the clutch tube. Refer to CL-8, "Air Bleeding Procedure" .
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CL-13
CLUTCH RELEASE MECHANISM
[RS6F51R]
CLUTCH RELEASE MECHANISM Removal and Installation
PFP:30502
ECS0095A
SCIA0328E
REMOVAL
1. 2. 3. 4.
q
Remove manual transaxle from the vehicle. Refer to MT-15, "TRANSAXLE ASSEMBLY" . Remove release bearing, holder spring, and withdrawal lever from inside the clutch housing. Remove dust cover. Remove retainer spring from the withdrawal lever. If release bearing is seized, damaged, not properly centered or does not rotate smoothly, replace it. If contact surface of the withdrawal lever is excessively worn, replace it. If dust cover is cracked, replace it.
INSPECTION AFTER REMOVAL
q
q
SCL733
INSTALLATION
CAUTION: q 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 judder. Wipe off any grease oozing from the parts. q Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or flywheel surface.
CL-14
CLUTCH RELEASE MECHANISM
[RS6F51R]
1. Following the instructions below, apply grease to the specified points.
A
B
CL
SCL815
D
2.
CAUTION: Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces. q Evenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring sliding surface. q Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of the release bearing. The grease surface should be level with the surrounding area. q Apply a thin coat of recommended grease evenly to the release bearing sliding surface. Install release bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing. Install in the reverse order of the removal.
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CL-15
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[RS6F51R]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Removal and Installation
PFP:30100
ECS0095B
MCIA0130E
CAUTION: Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or flywheel surface.
REMOVAL
1. 2. Remove manual transaxle from the vehicle. Refer to MT-15, "TRANSAXLE ASSEMBLY" . Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL Clutch Disc
q
Measure circumferential runout relative to the clutch disc center spline. If it is outside the specification, replace the clutch disc. Runout limit/diameter of the area to be measured: MODEL 240 1.0 mm (0.039 in) or less/230 mm (9.06 in) dia.
q
Measure clutch disc spline and input shaft spline backlash at the circumference of the disc. If outside the specification, replace. Maximum allowable spline backlash: MODEL 240 1.0 mm (0.039 in)
MCIA0131E
q
Using calipers, measure the depth to the clutch disc facing rivet heads. If it exceeds the allowable wear limit, replace the facing. Facing wear limit (depth to the rivet head): 0.3 mm (0.012 in)
MCIA0132E
CL-16
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[RS6F51R]
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height using a diaphragm adjusting wrench (special service tool). Tolerance for diaphragm spring lever unevenness: MODEL 240 0.7 mm (0.028 in)
q
A
B
q
Check clutch cover thrust ring for wear or breakage. If wear or CL breakage is found, replace clutch cover assembly. NOTE: q Worn thrust ring will generate a beating noise when tapped at D SCL466-C the rivet with a hammer. q Broken thrust ring will make a clinking sound when cover is shaken up and down. E 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.
F
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact surface. If runout is outside the specification, replace the flywheel. If a trace of burn or discoloration is found on the surface, repair it with sandpaper. Allowable flywheel runout: EM-221, "Flywheel Runout" CAUTION: Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).
AEM100
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H
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INSTALLATION
1. 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 judder. Wipe off any grease oozing from the parts. Install clutch disc and clutch cover. Pre-tighten mounting bolts and install clutch aligning bar.
Tool number ST20630000
J
K
2.
L
Engine type YD22DDTi
M
3.
Tighten clutch cover attaching bolts evenly in two steps in the order shown in the figure. Tightening torque: First step : 9.9 - 19 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb) Final step : 35 - 44 N·m (3.5 - 4.5 kg·m, 26 - 32 ft·lb)
4.
Install manual transaxle. Refer to MT-15, "TRANSAXLE ASSEMBLY" .
MCIA0133E
CL-17
SERVICE DATA AND SPECIFICATIONS (SDS)
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS) Clutch Control System
Type of clutch control Hydraulic
PFP:00030
ECS0095C
Clutch Master Cylinder
Inner diameter 15.87 (5/8)
ECS0095D
Unit: mm (in)
Clutch Operating Cylinder
Inner diameter 19.05 (3/4)
ECS0095E
Unit: mm (in)
Clutch Disc
Engine type Model Facing size (outer dia. × inner dia. × thickness) Thickness of disc assembly with lord Wear limit of facing surface to rivet head Runout limit/diameter of the area to be measured Maximum allowable spline backlash YD22DDTi 240 240 × 170 × 3.5 (9.45 × 6.69 × 0.138)
ECS0095F
Unit: mm (in)
7.5 - 8.1 (0.295 - 0.319) with 6,865 N (700.2 kg, 1543.3 lb) 0.3 (0.012) 1.0 (0.039) or less/230 (9.06) dia. 1.0 (0.039)
ECS0095G
Clutch Cover
Engine type Model Full-load Diaphragm spring lever height Uneven limit diaphragm spring toe height YD22DDTi 240 6,867 N (700.4 kg, 1543.7 lb) 37.0 - 39.0 (1.457 - 1.535) 0.7 (0.028)
Unit: mm (in)
Clutch Pedal
Clutch pedal stroke "S" Pedal free play "A" 155 - 160 (6.10 - 6.30) 1 - 3 (0.04 - 0.12)
ECS0095H
Unit: mm (in)
CL-18