NISSAN ALMERA N16 2003 Electronic Repair Manual

Components — RHD Model with QG Engine —NJCL0041
YCL027
1. Clutch pedal bracket
2. Pedal stopper bolt
3. Bush
4. Clutch pedal
5. Snap pin
6. Clevis pin
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Clutch disc
15. Clutch cover
16. Withdrawal lever17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring
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LC
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HA
SC
EL
IDX
CLUTCH SYSTEM
Components — RHD Model with QG Engine —
CL-5

Components — LHD Model with QG Engine —NJCL0048
SCL844
1. Clutch pedal bracket
2. Clevis pin
3. Bush
4. Snap pin
5. Pedal stopper bolt
6. Clutch pedal
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Clutch disc
15. Clutch cover
16. Withdrawal lever17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring
CLUTCH SYSTEM
Components — LHD Model with QG Engine —
CL-6

Components — RHD Model with YD Engine —NJCL0005
YCL006
1. Clutch pedal bracket
2. Pedal stopper bolt
3. Bush
4. Clutch pedal
5. Snap pin
6. Clevis pin
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Air bleeder screw
15. Withdrawal lever16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer
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CLUTCH SYSTEM
Components — RHD Model with YD Engine —
CL-7

Components — LHD Model with YD Engine —NJCL0049
SCL846
1. Clutch pedal bracket
2. Clevis pin
3. Bush
4. Snap pin
5. Pedal stopper bolt
6. Clutch pedal
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Air bleeder screw
15. Withdrawal lever16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer
CLUTCH SYSTEM
Components — LHD Model with YD Engine —
CL-8

Inspection and AdjustmentNJCL0006CLUTCH PEDAL INSPECTIONNJCL0006S03Pedal StrokeNJCL0006S0301Check clutch pedal stroke by using a 1–meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver’s seat to set a ref-
erence 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 stroke in the table, adjust actual pedal
stroke if necessary (refer to“CLUTCH PEDAL ADJUSTMENT”).
NOTE:
Do not use steering wheel as a reference point, angle gives
incorrect reading.
Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.
NCL058
SCL702
Pedal Free PlayNJCL0006S0302Check pedal free play, if out of specification refer to“CLUTCH
PEDAL ADJUSTMENT”
Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
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CLUTCH SYSTEM
Inspection and Adjustment
CL-9

CLUTCH PEDAL ADJUSTMENTNJCL0006S04Pedal StrokeNJCL0006S04011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free
play.
Pedal stroke “S”.
Refer to “SDS”, CL-24.
Pedal Free PlayNJCL0006S04021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. 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”.
Refer to “SDS”, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENJCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing 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.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, then air bubbles
will no longer appear at the damper in the brake fluid.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont’d)
CL-10

ComponentsNJCL0007
SCL840-A
SCL847-A
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CLUTCH MASTER CYLINDER
Components
CL-11

RemovalNJCL00081. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
InstallationNJCL00091. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
: 11 - 14 N·m (1.1 - 1.5 kg-m, 8 - 10 ft-lb)
3. Tighten clutch tube flare nut using a flare nut torque wrench.
: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. After installing clevis pin, install snap pin to connect clutch
pedal to push rod.
5. After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to “Air Bleeding
Procedure”, CL-10.)
SCL725
DisassemblyNJCL00101. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
InspectionNJCL0011Check the following items, and replace if necessary.
Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
Piston with piston cup, for wear or damage
Return spring, for wear or damage
Dust cover, for cracks, deformation or damage
Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Removal
CL-12

AssemblyNJCL00121. Apply rubber lubricant to the sliding part of piston assembly,
and insert piston assembly.
2. After installing stopper to push rod, install stopper ring while
keeping piston assembly depressed by hand, so that piston
assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring
for assembly.
3. Install dust cover.
4. Install clevis to push rod, and tighten lock nut A to the speci-
fied torque.
: 8 - 10 N·m (0.8 - 1.1 kg-m, 70 - 95 in-lb)
5. Install spring pin using a pin punch.
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CLUTCH MASTER CYLINDER
Assembly
CL-13

ComponentsNJCL0019
YCL003
RemovalNJCL00201. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove union bolt and clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolts, and remove cylin-
der from vehicle.
DisassemblyNJCL0021Remove dust cover, and remove piston assembly from cylinder
body.
InspectionNJCL0022Inspect for following, and replace parts if necessary.
Damage, foreign material, wear, rust, and pinholes on the cyl-
inder inner surface, piston, and sliding part of piston cup
Weak spring
Crack and deformation of dust cover
OPERATING CYLINDER
Components
CL-14