Clutch master NISSAN TERRANO 2004 Service Repair Manual

TIGHTENING TORQUE
UnitN×m kg-m ft-lb
Clutch Pedal stopper lock nut 12 - 15 1.2 - 1.5 8.7 - 10.8
Master cylinder push rod
lock nut 8 - 11 0.8 - 1.1 5.8 - 8.0
Manual transmission Drain and filler plugsFS5R30A 25 - 34 2.5 - 3.5 18 - 25
Differential carrier Drain and filler plugsR180A 39 - 59 4 - 6 28.8 - 43.5
H233B 59 - 98 6 - 10 43.5 - 72.3
Front axle and front suspen-
sion Tie-rod lock nut 60 - 70 6.1 - 7.1 44.3 - 51.6
Brake system Air bleeder valve 7 - 9 0.7 - 0.9 5.1 - 6.5
Wheel and tire
Wheel nut 118 - 147 12.0 - 15.0 87.0 -
108.4
SERVICE AND SPECIFICATIONS (SDS)
Chassis and Body Maintenance (Cont'd)
MA-50
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CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS AND PREPARATION ............................2
Precautions ..................................................................2
Preparation ..................................................................2
CLUTCH SYSTEM ...........................................................3
Clutch Pedal ................................................................4
INSPECTION AND ADJUSTMENT .................................5
Adjusting Clutch Pedal ................................................5
Bleeding Procedure .....................................................6
CLUTCH MASTER CYLINDER .......................................7
HYDRAULIC CLUTCH CONTROL .................................8Clutch Master Cylinder ................................................8
Clutch Operating Cylinder ...........................................8
CLUTCH RELEASE MECHANISM .................................9
CLUTCH DISC AND CLUTCH COVER ........................ 11
Clutch Disc................................................................. 11
Clutch Cover and Flywheel .......................................12
SERVICE DATA AND SPECIFICATIONS (SDS) ..........14
General Specifications ...............................................14
Inspection and Adjustment ........................................14
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Precautions
IRecommended fluid is brake fluid ªDOT 4º.
I Do not reuse drained brake fluid.
I Be careful not to splash brake fluid on painted areas.
I When removing and installing clutch piping, use Tool.
I To clean or wash all parts of master cylinder, operating
cylinder and clutch damper, use clean brake fluid.
I Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
Remove all dust from clutch disc with a dust collector after
cleaning with waste cloth.
Preparation
SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool name Description
ST20050010
Base plate
Inspecting diaphragm spring of clutch cover
ST20050100
Distance piece
Inspecting diaphragm spring of clutch cover
GG94310000
Flare nut torque
wrench
Removing and installing each clutch piping
KV30100100*
Clutch aligning bar
Installing clutch cover and clutch disc
ST20050240*
Diaphragm spring
adjusting wrench
Adjusting unevenness of diaphragm spring of clutch
cover
SBR820B
PRECAUTIONS AND PREPARATION
CL-2
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Adjusting Clutch Pedal
1. Adjust pedal height with pedal stopper.Pedal height ªHº:LHD: 227 - 237 mm (8.94 - 9.33 in)
RHD: 210 - 220 mm (8.27 - 8.66 in)
2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut.Pedal free play ªAº: 1.0 - 3.0 mm (0.039 - 0.118 in)
YCL009
INSPECTION AND ADJUSTMENT
CL-5
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Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the follow-ing 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 of clutch damper.
c. Fully depress clutch pedal several times.
d. With clutch pedal depressed, open bleeder valve to release air.
e. Close bleeder valve.
f. Repeat steps (c) through (e) above until brake fluid flows from air bleeder valve without air bubbles.
2. Bleed air from clutch operating cylinder according to the above procedure.
3. Repeat the above bleeding procedures 1 and 2 several times.
NCL025
INSPECTION AND ADJUSTMENT
CL-6
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NCL028
CLUTCH MASTER CYLINDER
CL-7
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Clutch Master Cylinder
INSPECTION
ICheck cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check return spring for wear or damage. Replace if necessary.
I Check reservoir for deformation or damage. Replace if neces-
sary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
Clutch Operating Cylinder
INSPECTION
ICheck rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check piston spring for wear or damage. Replace if necessary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
SCL420-A
HYDRAULIC CLUTCH CONTROL
CL-8
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General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch controlHydraulic
CLUTCH MASTER CYLINDER
Inner diametermm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
EngineTD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness) 250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load 7.0 - 7.4 (0.276 - 0.291)
Under a load of 5,884 N (600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27TiZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHDRHD
Pedal height* 227 - 237
(8.94 - 9.33) 210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis) 1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27TiZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head 0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center) 120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc) 1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine
TD27TiZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14
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A
ABS (anti-lock brake system).........................BR-36
ABS - Wiring diagram ....................................BR-51
A/C air flow .......................................................HA-8
A/C compressor precaution..............................HA-5
A/C control operation (manual A/C) .................HA-6
A/C relay.........................................................HA-61
A/C symptom chart (manual A/C) ..................HA-36
A/C trouble diagnoses (manual A/C) .............HA-27
A/C, M - Wiring diagram ................................HA-43
ACC/SW - Wiring diagram ...........................EC-106
Accelerator control system ...........................FE-2, 5
Accelerator position sensor .........EC-130, 391, 394
Accelerator position switch ..................EC-392, 394
Accelerator switch (F/C) ...............................EC-104
Accelerator wire adjustment .............................FE-5
Accelerator work unit....................................EC-388
A/CCUT - Wiring diagram ............................EC-308
Air bag ..............................................................RS-8
Air bag disposal..............................................RS-22
Air bag precautions ...........................................GI-3
Air bleeding (hydraulic clutch) ..........................CL-6
Air bleeding for brake system ..........................BR-8
Air cleaner filter replacement ..............MA-5, 20, 24
Air conditioner cut control ..............EC-22, 334, 463
Air control cable adjustment...........................HA-62
Air flow meter - See Mass air flowsensor .................................................EC-88, 379
Alternator ........................................................SC-27
Angular tightening application..........................EM-3
Antenna.................................................EL-134, 150
Anti-lock brake system - See ABS .................BR-38
Anti-lock brake system - Wiring diagram .......................................................BR-51
APS - Wiring diagram ..................................EC-133
ASCD vacuum hose ......................................MA-40
A/T - Wiring diagram .........................................AT-7
A/T - Wiring diagram - AT - PNP/SW .............AT-89
A/T - Wiring diagram - AT - VSS A/T ..............AT-51
A/T control ....................................................EC-160
A/T diagnosis communication line ...............EC-160
A/T fluid checking ............................................AT-27
A/T fluid temperature sensor...........................AT-78
A/T mode switch..............................................AT-99
A/T self-diagnoses ....................................AT-14, 19
A/T Wiring diagram - AT - ENG SS ................AT-81
A/T Wiring diagram AT - BA/FTS ....................AT-77
A/T Wiring diagram AT - LPSV .......................AT-84
A/T Wiring diagram AT - OVRCSV .................AT-70
A/T Wiring diagram AT - SSV/A ......................AT-64
A/T Wiring diagram AT - SSV/B ......................AT-67
A/T Wiring diagram AT - TCV .........................AT-73
A/T Wiring diagram AT - TPS..........................AT-58
A/T Wiring diagram AT - VSSMTR .................AT-54
AT/C - Wiring diagram..................................EC-162
Audio .....................................................EL-134, 136
AUDIO - Wiring diagram ...............................EL-138 Audio and A/C control removal and
installation - See Instrument panel .............BT-16
Auto lock free running hub .............................FA-14
Automatic transmission number ......................GI-29
Axle housing (rear) ...........................................RA-8
B
Back Door .......................................................BT-14
Back door opener - See Back door ................BT-14
Back door trim.................................................BT-18
Back door window...........................................BT-43
Back-up lamp ..................................................EL-53
Back-up lamp switch (M/T) ........................MT-6, 10
BACK/L - Wiring diagram................................EL-53
Ball joint front axle ..........................................FA-36
Basic inspection .....................................EC-50, 361
Battery ..............................................................SC-3
Blower motor ..................................................HA-60
Blower resistor................................................HA-60
Body alignment ...............................................BT-49
BOOST - Wiring diagram .............................EC-222
Boring/horning cylinder block.........................EM-74
Brake booster .................................................BR-18
Brake fluid change ...........................................BR-5
Brake fluid level ...........................MA-17, 36, 40, 43
Brake fluid level and line check .......................BR-5
Brake hydraulic line......................................BR-5, 6
Brake inspection ..........................MA-36, 40, 41, 42
Brake lines and cables inspection.....MA-36, 40, 42
Brake lining wear temporary checking ....MA-36, 42
Brake master cylinder ....................................BR-17
Brake pedal ....................................................BR-14
Brake switch .................................................EC-423
BRK/SW - Wiring diagram ...........................EC-210
Bumper, front ....................................................BT-6
Bumper, rear .....................................................BT-8C
Camshaft ........................................................EM-30
Camshaft position sensor (PUMP)...............EC-166
Center case (Transfer) ......................................TF-9
CHARGE - Wiring diagram ............................SC-24
Charge air pressure sensor .........................EC-220
Charging system ............................................SC-23
Chassis and body maintenance ....................MA-36
CIGAR - Wiring diagram ...............................EL-123
Cigarette lighter.............................................EL-122
Circuit breaker.................................................EL-19
CKPS - Wiring diagram ................................EC-154
Clock .............................................................EL-122
CLOCK - Wiring diagram ..............................EL-124
Clutch cover ..............................................CL-11, 12
Clutch disc ......................................................CL-11
Clutch fluid level ......................................MA-17, 36
Clutch master cylinder ..................................CL-7, 8
Clutch pedal .............................................CL-3, 4, 5
ALPHABETICAL INDEX
IDX-2
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INT/V - Wiring diagram ................................EC-282
Intake air control valve control solenoidvalve .........................................................EC-281
Intake Air Volume .........................................EC-150
Intake door control linkage adjustment ..........HA-63
Intake manifold...............................................EM-12
Interior .............................................................BT-18
Interior lamp ..............................................EL-67, 74
Interior lamp on-off control..............................EL-73
ISO 15031-2 Terminology................................GI-34
K
Knuckle spindle ...............................................FA-20 L
License lamp ...................................................EL-49
Limited slip diff. adjustment............................PD-45
Limited slip diff. assembly ..............................PD-47
Limited slip diff. disassembly ...................PD-43, 44
Limited slip diff. inspection .............................PD-44
Line pressure solenoid valve ..........................AT-86
Line pressure test (A/T) ..........................AT-30, 201
Liquid gasket application .................................EM-3
Location of electrical units ............EL-275, 276, 278
Lock, door ...........................................BT-10, 12, 14
Low and reverse brake .................................AT-166
LSV (Load sensing valve) ..............................BR-10
Lubricants.......................................................MA-17
Lubrication circuit (engine) .........................LC-3, 20
Lubrication oil A/C (checking andadjusting) ....................................................HA-22
Lubrication oil A/C (SDS) ...............................HA-64
Lubrication-locks, hinges and hood latches ..................................................MA-36, 45
Luggage compartment trim .............................BT-18
M
MAFS - Wiring diagram..................................EC-90
MAIN - Wiring diagram...................................EC-80
Main drive gear (M/T) .....................................MT-11
Main gear (Transfer) .................................TF-10, 21
Mainshaft (M/T) ..............................................MT-11
Mainshaft (Transfer)..................................TF-10, 17
Maintenance ...........MA-5, 8, 11, 14, 20, 36, 48, 49
MAJOR OVERHALL .....................................AT-124
Major overhaul (Transfer) .................................TF-9
Malfunction indicator (MI).......................EC-34, 345
Manifold tightening torque (intake &exhaust) ...............................................MA-20, 28
Manual transmission number ..........................GI-29
Manual transmission oil replacement ......MA-36, 37
Map lamp ........................................................EL-74
Mass air flow sensor (MAFS) ................EC-88, 379
Master cylinder (brake) ..................................BR-17 Meter .........................................................EL-82, 85
METER - Wiring diagram................................EL-86
MIL/DL - Wiring diagram ..............................EC-310
MIRROR - Wiring diagram............................EL-154
Mirror, door......................................................BT-48
Model variation ................................................GI-27
Molding - See Exterior ....................................BT-21
M/T major overhaul ........................................MT-10
M/T removal and installation ........................MT-7, 8
Mud guard - See Exterior ...............................BT-21
MULTI - Wiring diagram................................EL-205
Multi-remote control
system ..............................EL-202, 204, 213, 215
Multiport fuel injection precautions ....................GI-5
N
NATS (Nissan anti-theftsystem) .....................EL-222, 223, 224, 231, 242
NATS - Wiring diagram .................................EL-225
NATS V2.0 precautions (For Europe) ...............GI-4
Needle lift sensor .........................................EC-450
NVH troubleshooting (EM) ...............................EM-8
O
Oil change (capacity) ............MA-21, 29, 37, 38, 39
Oil change (interval) ..................................MA-5, 35
Oil cooler (engine) ............................................LC-8
Oil pan (engine) .............................................EM-22
Oil pump (A/T)...............................................AT-139
Oil seal replacement (engine)........................EM-50
Oil seal replacement (front final drive4WD)...........................................................PD-10
OILPSW - Wiring diagram............................EC-474
On board diagnostic system ..................EC-33, 344
Overdrive control switch................................AT-100
Overheat .......................................................EC-109
Overrun clutch solenoid valve ..................AT-71, 72
Oversize piston ..............................................EM-74
P
Park/Neutral position switch .........................EC-256
Park/neutral position switch (A/T) ...........AT-93, 119
Parking drum brake ........................................BR-36
Parking lamp ...................................................EL-49
PCV (positive crankcase ventilation) .....EC-23, 335
Periodic maintenance ......................................MA-5
Piston pin inspection ......................................EM-71
Piston ring inspection.....................................EM-72
PNP/SW - Wiring diagram ...........................EC-257
POWER - Wiring diagram...............................EL-10
Power doorlock ...........EL-163, 164, 171, 179, 180, 182, 192
Power steering fluid level...............MA-36, 44, ST-4
Power steering gear .................................ST-12, 22
ALPHABETICAL INDEX
IDX-5
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